Apparatus for radially expanding and plastically deforming a tubular member

ABSTRACT

An apparatus and method for radially expanding and plastically deforming a tubular member. The apparatus includes a support member, an expansion device coupled to the support member and at least one of a cutting device coupled to the support member, an actuator coupled to the support member, a sealing assembly, or a packer assembly coupled to the support member. The apparatus may further include a gripping device for coupling the tubular member to the support member. The expansion device may be used for radially expanding and plastically deforming the tubular member which may be coupled to the support member. The cutting device may be used for cutting the tubular member. The actuator may be used for displacing the expansion device relative to the support member. The sealing assembly may be used for sealing an annulus defined between the support member and the tubular member.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of the filing date of U.S.provisional patent application Ser. No. 60/453,678, filed on Mar. 11,2003, the disclosure of which is incorporated herein by reference.

The present application is a continuation-in-part of the following: (1)PCT patent application Ser. No. PCT/US02/36157, filed on Nov. 12, 2002,(2) PCT patent application Ser. No. PCT/US02/36267, filed on Nov. 12,2002, (3) PCT patent application Ser. No. PCT/US03/04837, filed on Feb.29, 2003, (4) PCT patent application Ser. No. PCT/US03/29859, filed onSep. 22, 2003, (5) PCT patent application Ser. No. PCT/US03/14153, filedon Nov. 13, 2003, (6) PCT patent application Ser. No. PCT/US03/18530,filed on Jun. 11, 2003, (7) PCT patent application Ser. No.PCT/US03/29858, and (8) PCT patent application Ser. No. PCT/US03/29460,filed on Sep. 23, 2003, filed on Sep. 22, 2003, the disclosures of whichare incorporated herein by reference.

This application is related to the following co-pending applications:(1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent applicationSer. No. 09/454,139, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, whichclaims priority from provisional application 60/121,702, filed on Feb.25, 1999, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb.10, 2000, which claims priority from provisional application 60/119,611,filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed asU.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999,which claims priority from provisional application 60/108,558, filed onNov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, filed onJul. 1, 2002, which claims priority from provisional application60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application Ser. No.09/523,468, filed on Mar. 10, 2000, which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S.Pat. No. 6,568,471, which was filed as patent application Ser. No.09/512,895, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S.Pat. No. 6,575,240, which was filed as patent application Ser. No.09/511,941, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S.Pat. No. 6,557,640, which was filed as patent application Ser. No.09/588,946, filed on Jun. 7, 2000, which claims priority fromprovisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S.patent application Ser. No. 09/981,916, filed on Oct. 18, 2001 as acontinuation-in-part application of U.S. Pat. No. 6,328,113, which wasfiled as U.S. patent application Ser. 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No. 09/679,907, on Oct. 5, 2000,which claims priority from provisional patent application Ser. No.60/159,082, filed on Oct. 12, 1999, (18) U.S. patent application Ser.No. 10/089,419, filed on Mar. 27, 2002, which claims priority fromprovisional patent application Ser. No. 60/159,039, filed on Oct. 12,1999, (19) U.S. patent application Ser. No. 09/679,906, filed on Oct. 5,2000, which claims priority from provisional patent application Ser. No.60/159,033, filed on Oct. 12, 1999, (20) U.S. patent application Ser.No. 10/303,992, filed on Nov. 22, 2002, which claims priority fromprovisional patent application Ser. No. 60/212,359, filed on Jun. 19,2000, (21) U.S. provisional patent application Ser. No. 60/165,228,filed on Nov. 12, 1999, (22) U.S. provisional patent application Ser.No. 60/455,051, filed on Mar. 14, 2003, (23) PCT application US02/2477,filed on Jun. 26, 2002, which claims priority from U.S. provisionalpatent application Ser. No. 60/303,711, filed on Jul. 6, 2001, (24) U.S.patent application Ser. No. 10/311,412, filed on Dec. 12, 2002, whichclaims priority from provisional patent application Ser. No. 60/221,443,filed on Jul. 28, 2000, (25) U.S. patent application serial no.10/322,947, filed on Dec. 18, 2002, which claims priority fromprovisional patent application Ser. No. 60/221,645, filed on Jul. 28,2000, (26) U.S. patent application Ser. No. 10/322,947, filed on Jan.22, 2003, which claims priority from provisional patent application Ser.No. 60/233,638, filed on Sep. 18, 2000, (27) U.S. patent applicationSer. No. 10/406,648, filed on Mar. 31, 2003, which claims priority fromprovisional patent application Ser. No. 60/237,334, filed on Oct. 2,2000, (28) PCT application US02/04353, filed on Feb. 14, 2002, whichclaims priority from U.S. provisional patent application Ser. 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BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas exploration, and inparticular to forming and repairing wellbore casings to facilitate oiland gas exploration.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member, a cutting device forcutting the tubular member coupled to the support member, and anexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member, an expansion devicefor radially expanding and plastically deforming the tubular membercoupled to the support member, and an actuator coupled to the supportmember for displacing the expansion device relative to the supportmember.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member; an expansion devicefor radially expanding and plastically deforming the tubular membercoupled to the support member; and a sealing assembly for sealing anannulus defined between the support member and the tubular member.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member; a first expansiondevice for radially expanding and plastically deforming the tubularmember coupled to the support member; and a second expansion device forradially expanding and plastically deforming the tubular member coupledto the support member.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member; an expansion devicefor radially expanding and plastically deforming the tubular membercoupled to the support member; and a packer coupled to the supportmember.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a support member; a cutting device forcutting the tubular member coupled to the support member; a grippingdevice for gripping the tubular member coupled to the support member; asealing device for sealing an interface with the tubular member coupledto the support member; a locking device for locking the position of thetubular member relative to the support member; a first adjustableexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member; a second adjustableexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member; a packer coupled to thesupport member; and an actuator for displacing one or more of thesealing assembly, first and second adjustable expansion devices, andpacker relative to the support member.

According to another aspect of the present invention, an apparatus forcutting a tubular member is provided that includes a support member; anda plurality of movable cutting elements coupled to the support member.

According to another aspect of the present invention, an apparatus forengaging a tubular member is provided that includes a support member;and a plurality of movable elements coupled to the support member.

According to another aspect of the present invention, an apparatus forgripping a tubular member is provided that includes a plurality ofmovable gripping elements.

According to another aspect of the present invention, an actuator isprovided that includes a tubular housing; a tubular piston rod movablycoupled to and at least partially positioned within the housing; aplurality of annular piston chambers defined by the tubular housing andthe tubular piston rod; and a plurality of tubular pistons coupled tothe tubular piston rod, each tubular piston movably positioned within acorresponding annular piston chamber.

According to another aspect of the present invention, an apparatus forcontrolling a packer is provided that includes a tubular support member;one or more drag blocks releasably coupled to the tubular supportmember; and a tubular stinger coupled to the tubular support member forengaging the packer.

According to another aspect of the present invention, a packer isprovided that includes a support member defining a passage; a shoecomprising a float valve coupled to an end of the support member; one ormore compressible packer elements movably coupled to the support member;and a sliding sleeve valve movably positioned within the passage of thesupport member.

According to another aspect of the present invention, a method ofradially expanding and plastically deforming an expandable tubularmember within a borehole having a preexisting wellbore casing isprovided that includes positioning the tubular member within theborehole in overlapping relation to the wellbore casing; radiallyexpanding and plastically deforming a portion of the tubular member toform a bell section; and radially expanding and plastically deforming aportion of the tubular member above the bell section comprising aportion of the tubular member that overlaps with the wellbore casing;wherein the inside diameter of the bell section is greater than theinside diameter of the radially expanded and plastically deformedportion of the tubular member above the bell section.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing is provided that includespositioning an adjustable expansion device within a first expandabletubular member; supporting the first expandable tubular member and theadjustable expansion device within a borehole; lowering the adjustableexpansion device out of the first expandable tubular member; increasingthe outside dimension of the adjustable expansion device; displacing theadjustable expansion device upwardly relative to the first expandabletubular member m times to radially expand and plastically deform mportions of the first expandable tubular member within the borehole;positioning the adjustable expansion device within a second expandabletubular member; supporting the second expandable tubular member and theadjustable expansion device within the borehole in overlapping relationto the first expandable tubular member; lowering the adjustableexpansion device out of the second expandable tubular member; increasingthe outside dimension of the adjustable expansion device; and displacingthe adjustable expansion device upwardly relative to the secondexpandable tubular member n times to radially expand and plasticallydeform n portions of the second expandable tubular member within theborehole.

According to another aspect of the present invention, a method forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes positioning anadjustable expansion device within the expandable tubular member;supporting the expandable tubular member and the adjustable expansiondevice within the borehole; lowering the adjustable expansion device outof the expandable tubular member; increasing the outside dimension ofthe adjustable expansion device; displacing the adjustable expansionmandrel upwardly relative to the expandable tubular member n times toradially expand and plastically deform n portions of the expandabletubular member within the borehole; and pressurizing an interior regionof the expandable tubular member above the adjustable expansion deviceduring the radial expansion and plastic deformation of the expandabletubular member within the borehole.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing is provided that includespositioning an adjustable expansion device within a first expandabletubular member; supporting the first expandable tubular member and theadjustable expansion device within a borehole; lowering the adjustableexpansion device out of the first expandable tubular member; increasingthe outside dimension of the adjustable expansion device; displacing theadjustable expansion device upwardly relative to the first expandabletubular member m times to radially expand and plastically deform mportions of the first expandable tubular member within the borehole;pressurizing an interior region of the first expandable tubular memberabove the adjustable expansion device during the radial expansion andplastic deformation of the first expandable tubular member within theborehole; positioning the adjustable expansion mandrel within a secondexpandable tubular member; supporting the second expandable tubularmember and the adjustable expansion mandrel within the borehole inoverlapping relation to the first expandable tubular member; loweringthe adjustable expansion mandrel out of the second expandable tubularmember; increasing the outside dimension of the adjustable expansionmandrel; displacing the adjustable expansion mandrel upwardly relativeto the second expandable tubular member n times to radially expand andplastically deform n portions of the second expandable tubular memberwithin the borehole; and pressurizing an interior region of the secondexpandable tubular member above the adjustable expansion mandrel duringthe radial expansion and plastic deformation of the second expandabletubular member within the borehole.

According to another aspect of the present invention, a method forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes positioning first andsecond adjustable expansion devices within the expandable tubularmember; supporting the expandable tubular member and the first andsecond adjustable expansion devices within the borehole; lowering thefirst adjustable expansion device out of the expandable tubular member;increasing the outside dimension of the first adjustable expansiondevice; displacing the first adjustable expansion device upwardlyrelative to the expandable tubular member to radially expand andplastically deform a lower portion of the expandable tubular member;displacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the expandabletubular member; decreasing the outside dimension of the first adjustableexpansion device and increasing the outside dimension of the secondadjustable expansion device; displacing the second adjustable expansiondevice upwardly relative to the expandable tubular member to radiallyexpand and plastically deform portions of the expandable tubular memberabove the lower portion of the expandable tubular member; wherein theoutside dimension of the first adjustable expansion device is greaterthan the outside dimension of the second adjustable expansion device.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing is provided that includespositioning first and second adjustable expansion devices within a firstexpandable tubular member; supporting the first expandable tubularmember and the first and second adjustable expansion devices within aborehole; lowering the first adjustable expansion device out of thefirst expandable tubular member; increasing the outside dimension of thefirst adjustable expansion device; displacing the first adjustableexpansion device upwardly relative to the first expandable tubularmember to radially expand and plastically deform a lower portion of thefirst expandable tubular member; displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the first expandable tubular member; decreasing the outsidedimension of the first adjustable expansion device and increasing theoutside dimension of the second adjustable expansion device; displacingthe second adjustable expansion device upwardly relative to the firstexpandable tubular member to radially expand and plastically deformportions of the first expandable tubular member above the lower portionof the expandable tubular member; positioning first and secondadjustable expansion devices within a second expandable tubular member;supporting the first expandable tubular member and the first and secondadjustable expansion devices within the borehole in overlapping relationto the first expandable tubular member; lowering the first adjustableexpansion device out of the second expandable tubular member; increasingthe outside dimension of the first adjustable expansion device;displacing the first adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform a lower portion of the second expandable tubular member;displacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the second expandabletubular member; decreasing the outside dimension of the first adjustableexpansion device and increasing the outside dimension of the secondadjustable expansion device; and displacing the second adjustableexpansion device upwardly relative to the second expandable tubularmember to radially expand and plastically deform portions of the secondexpandable tubular member above the lower portion of the secondexpandable tubular member; wherein the outside dimension of the firstadjustable expansion device is greater than the outside dimension of thesecond adjustable expansion device.

According to another aspect of the present invention, a method forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes positioning first andsecond adjustable expansion devices within the expandable tubularmember; supporting the expandable tubular member and the first andsecond adjustable expansion devices within the borehole; lowering thefirst adjustable expansion device out of the expandable tubular member;increasing the outside dimension of the first adjustable expansiondevice; displacing the first adjustable expansion device upwardlyrelative to the expandable tubular member to radially expand andplastically deform a lower portion of the expandable tubular member;pressurizing an interior region of the expandable tubular member abovethe first adjustable expansion device during the radial expansion of thelower portion of the expandable tubular member by the first adjustableexpansion device; displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to theexpandable tubular member; decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; displacing the second adjustableexpansion device upwardly relative to the expandable tubular member toradially expand and plastically deform portions of the expandabletubular member above the lower portion of the expandable tubular member;and pressurizing an interior region of the expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the expandable tubular member above the lower portionof the expandable tubular member by the second adjustable expansiondevice; wherein the outside dimension of the first adjustable expansiondevice is greater than the outside dimension of the second adjustableexpansion device.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing is provided that includespositioning first and second adjustable expansion devices within a firstexpandable tubular member; supporting the first expandable tubularmember and the first and second adjustable expansion devices within aborehole; lowering the first adjustable expansion device out of thefirst expandable tubular member; increasing the outside dimension of thefirst adjustable expansion device; displacing the first adjustableexpansion device upwardly relative to the first expandable tubularmember to radially expand and plastically deform a lower portion of thefirst expandable tubular member; pressurizing an interior region of thefirst expandable tubular member above the first adjustable expansiondevice during the radial expansion of the lower portion of the firstexpandable tubular member by the first adjustable expansion device;displacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the first expandabletubular member; decreasing the outside dimension of the first adjustableexpansion device and increasing the outside dimension of the secondadjustable expansion device; displacing the second adjustable expansiondevice upwardly relative to the first expandable tubular member toradially expand and plastically deform portions of the first expandabletubular member above the lower portion of the expandable tubular member;pressurizing an interior region of the first expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the first expandable tubular member above the lowerportion of the first expandable tubular member by the second adjustableexpansion device; positioning first and second adjustable expansiondevices within a second expandable tubular member; supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within the borehole in overlapping relation to the firstexpandable tubular member; lowering the first adjustable expansiondevice out of the second expandable tubular member; increasing theoutside dimension of the first adjustable expansion device; displacingthe first adjustable expansion device upwardly relative to the secondexpandable tubular member to radially expand and plastically deform alower portion of the second expandable tubular member; pressurizing aninterior region of the second expandable tubular member above the firstadjustable expansion device during the radial expansion of the lowerportion of the second expandable tubular member by the first adjustableexpansion device; displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the secondexpandable tubular member; decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; displacing the second adjustableexpansion device upwardly relative to the second expandable tubularmember to radially expand and plastically deform portions of the secondexpandable tubular member above the lower portion of the secondexpandable tubular member; and pressurizing an interior region of thesecond expandable tubular member above the second adjustable expansiondevice during the radial expansion of the portions of the secondexpandable tubular member above the lower portion of the secondexpandable tubular member by the second adjustable expansion device;wherein the outside dimension of the first adjustable expansion deviceis greater than the outside dimension of the second adjustable expansiondevice.

According to another aspect of the present invention, a method forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes supporting theexpandable tubular member, an hydraulic actuator, and an adjustableexpansion device within the borehole; increasing the size of theadjustable expansion device; and displacing the adjustable expansiondevice upwardly relative to the expandable tubular member using thehydraulic actuator to radially expand and plastically deform a portionof the expandable tubular member.

According to another aspect of the present invention, a method forforming a mono diameter wellbore casing within a borehole that includesa preexisting wellbore casing is provided that includes supporting theexpandable tubular member, an hydraulic actuator, and an adjustableexpansion device within the borehole; increasing the size of theadjustable expansion device; displacing the adjustable expansion deviceupwardly relative to the expandable tubular member using the hydraulicactuator to radially expand and plastically deform a portion of theexpandable tubular member; and displacing the adjustable expansiondevice upwardly relative to the expandable tubular member to radiallyexpand and plastically deform the remaining portion of the expandabletubular member and a portion of the preexisting wellbore casing thatoverlaps with an end of the remaining portion of the expandable tubularmember.

According to another aspect of the present invention, a method ofradially expanding and plastically deforming a tubular member isprovided that includes positioning the tubular member within apreexisting structure; radially expanding and plastically deforming alower portion of the tubular member to form a bell section; and radiallyexpanding and plastically deforming a portion of the tubular memberabove the bell section.

According to another aspect of the present invention, a method ofradially expanding and plastically deforming a tubular member isprovided that includes applying internal pressure to the inside surfaceof the tubular member at a plurality of discrete location separated fromone another.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole having a preexisting wellbore casing isprovided that includes means for positioning the tubular member withinthe borehole in overlapping relation to the wellbore casing; means forradially expanding and plastically deforming a portion of the tubularmember to form a bell section; and means for radially expanding andplastically deforming a portion of the tubular member above the bellsection comprising a portion of the tubular member that overlaps withthe wellbore casing; wherein the inside diameter of the bell section isgreater than the inside diameter of the radially expanded andplastically deformed portion of the tubular member above the bellsection.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing is provided that includes meansfor positioning an adjustable expansion device within a first expandabletubular member; means for supporting the first expandable tubular memberand the adjustable expansion device within a borehole; means forlowering the adjustable expansion device out of the first expandabletubular member; means for increasing the outside dimension of theadjustable expansion device; means for displacing the adjustableexpansion device upwardly relative to the first expandable tubularmember m times to radially expand and plastically deform m portions ofthe first expandable tubular member within the borehole; means forpositioning the adjustable expansion device within a second expandabletubular member; means for supporting the second expandable tubularmember and the adjustable expansion device within the borehole inoverlapping relation to the first expandable tubular member; means forlowering the adjustable expansion device out of the second expandabletubular member; means for increasing the outside dimension of theadjustable expansion device; and means for displacing the adjustableexpansion device upwardly relative to the second expandable tubularmember n times to radially expand and plastically deform n portions ofthe second expandable tubular member within the borehole.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes means for positioningan adjustable expansion device within the expandable tubular member;means for supporting the expandable tubular member and the adjustableexpansion device within the borehole; means for lowering the adjustableexpansion device out of the expandable tubular member; means forincreasing the outside dimension of the adjustable expansion device;means for displacing the adjustable expansion mandrel upwardly relativeto the expandable tubular member n times to radially expand andplastically deform n portions of the expandable tubular member withinthe borehole; and means for pressurizing an interior region of theexpandable tubular member above the adjustable expansion device duringthe radial expansion and plastic deformation of the expandable tubularmember within the borehole.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing is provided that includes meansfor positioning an adjustable expansion device within a first expandabletubular member; means for supporting the first expandable tubular memberand the adjustable expansion device within a borehole; means forlowering the adjustable expansion device out of the first expandabletubular member; means for increasing the outside dimension of theadjustable expansion device; means for displacing the adjustableexpansion device upwardly relative to the first expandable tubularmember m times to radially expand and plastically deform m portions ofthe first expandable tubular member within the borehole; means forpressurizing an interior region of the first expandable tubular memberabove the adjustable expansion device during the radial expansion andplastic deformation of the first expandable tubular member within theborehole; means for positioning the adjustable expansion mandrel withina second expandable tubular member; means for supporting the secondexpandable tubular member and the adjustable expansion mandrel withinthe borehole in overlapping relation to the first expandable tubularmember; means for lowering the adjustable expansion mandrel out of thesecond expandable tubular member; means for increasing the outsidedimension of the adjustable expansion mandrel; means for displacing theadjustable expansion mandrel upwardly relative to the second expandabletubular member n times to radially expand and plastically deform nportions of the second expandable tubular member within the borehole;and means for pressurizing an interior region of the second expandabletubular member above the adjustable expansion mandrel during the radialexpansion and plastic deformation of the second expandable tubularmember within the borehole.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes means for positioningfirst and second adjustable expansion devices within the expandabletubular member; means for supporting the expandable tubular member andthe first and second adjustable expansion devices within the borehole;means for lowering the first adjustable expansion device out of theexpandable tubular member; means for increasing the outside dimension ofthe first adjustable expansion device; means for displacing the firstadjustable expansion device upwardly relative to the expandable tubularmember to radially expand and plastically deform a lower portion of theexpandable tubular member; means for displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the expandable tubular member; means for decreasing theoutside dimension of the first adjustable expansion device andincreasing the outside dimension of the second adjustable expansiondevice; means for displacing the second adjustable expansion deviceupwardly relative to the expandable tubular member to radially expandand plastically deform portions of the expandable tubular member abovethe lower portion of the expandable tubular member; wherein the outsidedimension of the first adjustable expansion device is greater than theoutside dimension of the second adjustable expansion device.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing is provided that includes meansfor positioning first and second adjustable expansion devices within afirst expandable tubular member; means for supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within a borehole; means for lowering the first adjustableexpansion device out of the first expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; displacing the first adjustable expansion device upwardlyrelative to the first expandable tubular member to radially expand andplastically deform a lower portion of the first expandable tubularmember; means for displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the firstexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe first expandable tubular member to radially expand and plasticallydeform portions of the first expandable tubular member above the lowerportion of the expandable tubular member; means for positioning firstand second adjustable expansion devices within a second expandabletubular member; means for supporting the first expandable tubular memberand the first and second adjustable expansion devices within theborehole in overlapping relation to the first expandable tubular member;means for lowering the first adjustable expansion device out of thesecond expandable tubular member; means for increasing the outsidedimension of the first adjustable expansion device; means for displacingthe adjustable expansion device upwardly relative to the secondexpandable tubular member to radially expand and plastically deform alower portion of the second expandable tubular member; means fordisplacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the second expandabletubular member; means for decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; and means for displacing the secondadjustable expansion device upwardly relative to the second expandabletubular member to radially expand and plastically deform portions of thesecond expandable tubular member above the lower portion of the secondexpandable tubular member; wherein the outside dimension of the firstadjustable expansion device is greater than the outside dimension of thesecond adjustable expansion device.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes means for positioningfirst and second adjustable expansion devices within the expandabletubular member; means for supporting the expandable tubular member andthe first and second adjustable expansion devices within the borehole;means for lowering the first adjustable expansion device out of theexpandable tubular member; means for increasing the outside dimension ofthe first adjustable expansion device; means for displacing the firstadjustable expansion device upwardly relative to the expandable tubularmember to radially expand and plastically deform a lower portion of theexpandable tubular member; means for pressurizing an interior region ofthe expandable tubular member above the first adjustable expansiondevice during the radial expansion of the lower portion of theexpandable tubular member by the first adjustable expansion device;means for displacing the first adjustable expansion device and thesecond adjustable expansion device downwardly relative to the expandabletubular member; means for decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; means for displacing the secondadjustable expansion device upwardly relative to the expandable tubularmember to radially expand and plastically deform portions of theexpandable tubular member above the lower portion of the expandabletubular member; and means for pressurizing an interior region of theexpandable tubular member above the second adjustable expansion deviceduring the radial expansion of the portions of the expandable tubularmember above the lower portion of the expandable tubular member by thesecond adjustable expansion device; wherein the outside dimension of thefirst adjustable expansion device is greater than the outside dimensionof the second adjustable expansion device.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing is provided that includes meansfor positioning first and second adjustable expansion devices within afirst expandable tubular member; means for supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within a borehole; means for lowering the first adjustableexpansion device out of the first expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; means for displacing the first adjustable expansion deviceupwardly relative to the first expandable tubular member to radiallyexpand and plastically deform a lower portion of the first expandabletubular member; means for pressurizing an interior region of the firstexpandable tubular member above the first adjustable expansion deviceduring the radial expansion of the lower portion of the first expandabletubular member by the first adjustable expansion device; means fordisplacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the first expandabletubular member; means for decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; means for displacing the secondadjustable expansion device upwardly relative to the first expandabletubular member to radially expand and plastically deform portions of thefirst expandable tubular member above the lower portion of theexpandable tubular member; means for pressurizing an interior region ofthe first expandable tubular member above the second adjustableexpansion device during the radial expansion of the portions of thefirst expandable tubular member above the lower portion of the firstexpandable tubular member by the second adjustable expansion device;means for positioning first and second adjustable expansion deviceswithin a second expandable tubular member; means for supporting thefirst expandable tubular member and the first and second adjustableexpansion devices within the borehole in overlapping relation to thefirst expandable tubular member; means for lowering the first adjustableexpansion device out of the second expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; means for displacing the first adjustable expansion deviceupwardly relative to the second expandable tubular member to radiallyexpand and plastically deform a lower portion of the second expandabletubular member; means for pressurizing an interior region of the secondexpandable tubular member above the first adjustable expansion deviceduring the radial expansion of the lower portion of the secondexpandable tubular member by the first adjustable expansion device;means for displacing the first adjustable expansion device and thesecond adjustable expansion device downwardly relative to the secondexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform portions of the second expandable tubular member above the lowerportion of the second expandable tubular member; and means forpressurizing an interior region of the second expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the second expandable tubular member above the lowerportion of the second expandable tubular member by the second adjustableexpansion device; wherein the outside dimension of the first adjustableexpansion device is greater than the outside dimension of the secondadjustable expansion device.

According to another aspect of the present invention, a system forradially expanding and plastically deforming an expandable tubularmember within a borehole is provided that includes means for supportingthe expandable tubular member, an hydraulic actuator, and an adjustableexpansion device within the borehole; means for increasing the size ofthe adjustable expansion device; and means for displacing the adjustableexpansion device upwardly relative to the expandable tubular memberusing the hydraulic actuator to radially expand and plastically deform aportion of the expandable tubular member.

According to another aspect of the present invention, a system forforming a mono diameter wellbore casing within a borehole that includesa preexisting wellbore casing is provided that includes means forsupporting the expandable tubular member, an hydraulic actuator, and anadjustable expansion device within the borehole; means for increasingthe size of the adjustable expansion device; means for displacing theadjustable expansion device upwardly relative to the expandable tubularmember using the hydraulic actuator to radially expand and plasticallydeform a portion of the expandable tubular member; and means fordisplacing the adjustable expansion device upwardly relative to theexpandable tubular member to radially expand and plastically deform theremaining portion of the expandable tubular member and a portion of thepreexisting wellbore casing that overlaps with an end of the remainingportion of the expandable tubular member.

According to another aspect of the present invention, a system forradially expanding and plastically deforming a tubular member isprovided that includes means for positioning the tubular member within apreexisting structure; means for radially expanding and plasticallydeforming a lower portion of the tubular member to form a bell section;and means for radially expanding and plastically deforming a portion ofthe tubular member above the bell section.

According to another aspect of the present invention, a system ofradially expanding and plastically deforming a tubular member isprovided that includes a support member; and means for applying internalpressure to the inside surface of the tubular member at a plurality ofdiscrete location separated from one another coupled to the supportmember.

According to another aspect of the present invention, a method ofcutting a tubular member is provided that includes positioning aplurality of cutting elements within the tubular member; and bringingthe cutting elements into engagement with the tubular member.

According to another aspect of the present invention, a method ofgripping a tubular member is provided that includes positioning aplurality of gripping elements within the tubular member; bringing thegripping elements into engagement with the tubular member. In anexemplary embodiment, bringing the gripping elements into engagementwith the tubular member includes displacing the gripping elements in anaxial direction; and displacing the gripping elements in a radialdirection.

According to another aspect of the present invention, a method ofoperating an actuator is provided that includes pressurizing a pluralityof pressure chamber.

According to another aspect of the present invention, a method ofinjecting a hardenable fluidic sealing material into an annulus betweena tubular member and a preexisting structure is provided that includespositioning the tubular member into the preexisting structure; sealingoff an end of the tubular member; operating a valve within the end ofthe tubular member; and injecting a hardenable fluidic sealing materialthrough the valve into the annulus between the tubular member and thepreexisting structure.

According to another aspect of the present invention, a system forcutting a tubular member is provided that includes means for positioninga plurality of cutting elements within the tubular member; and means forbringing the cutting elements into engagement with the tubular member.

According to another aspect of the present invention, a system forgripping a tubular member is provided that includes means forpositioning a plurality of gripping elements within the tubular member;and means for bringing the gripping elements into engagement with thetubular member.

According to another aspect of the present invention, an actuator systemis provided that includes a support member; and means for pressurizing aplurality of pressure chambers coupled to the support member. In anexemplary embodiment, the system further includes means for transmittingtorsional loads.

According to another aspect of the present invention, a system forinjecting a hardenable fluidic sealing material into an annulus betweena tubular member and a preexisting structure is provided that includesmeans for positioning the tubular member into the preexisting structure;means for sealing off an end of the tubular member; means for operatinga valve within the end of the tubular member; and means for injecting ahardenable fluidic sealing material through the valve into the annulusbetween the tubular member and the preexisting structure.

According to another aspect of the present invention, a method ofengaging a tubular member is provided that includes positioning aplurality of elements within the tubular member; and bringing theelements into engagement with the tubular member.

According to another aspect of the present invention, a system forengaging a tubular member is provided that includes means forpositioning a plurality of elements within the tubular member; and meansfor bringing the elements into engagement with the tubular member. In anexemplary embodiment, the elements include a first group of elements;and a second group of elements; wherein the first group of elements areinterleaved with the second group of elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross-sectional illustration of an embodiment ofa system for radially expanding and plastically deforming wellborecasing, including a tubular support member, a casing cutter, a ballgripper for gripping a wellbore casing, a force multiplier tensionactuator, a safety sub, a cup sub, a casing lock, an extension actuator,a bell section adjustable expansion cone assembly, a casing sectionadjustable expansion cone assembly, a packer setting tool, a packer, astinger, and an expandable wellbore casing, during the placement of thesystem within a wellbore.

FIG. 2 is a fragmentary cross-sectional illustration of the system ofFIG. 1 during the subsequent displacement of the bell section adjustableexpansion cone assembly, the casing section adjustable expansion coneassembly, the packer setting tool, the packer, and the stingerdownwardly out of the end of the expandable wellbore casing and theexpansion of the size of the bell section adjustable expansion coneassembly and the casing section adjustable expansion cone assembly.

FIG. 3 is a fragmentary cross-sectional illustration of the system ofFIG. 2 during the subsequent operation of the tension actuator todisplace the bell section adjustable expansion cone assembly upwardlyinto the end of the expandable wellbore casing to form a bell section inthe end of the expandable wellbore casing.

FIG. 4 is a fragmentary cross-sectional illustration of the system ofFIG. 3 during the subsequent reduction of the bell section adjustableexpansion cone assembly.

FIG. 5 is a fragmentary cross-sectional illustration of the system ofFIG. 4 during the subsequent upward displacement of the expanded casingsection adjustable expansion cone assembly to radially expand theexpandable wellbore casing.

FIG. 6 is a fragmentary cross-sectional illustration of the system ofFIG. 5 during the subsequent lowering of the tubular support member,casing cutter, ball gripper, a force multiplier tension actuator, safetysub, cup sub, casing lock, extension actuator, bell section adjustableexpansion cone assembly, casing section adjustable expansion coneassembly, packer setting tool, packer, and stinger and subsequentsetting of the packer within the expandable wellbore casing above thebell section.

FIG. 7 is a fragmentary cross-sectional illustration of the system ofFIG. 6 during the subsequent injection of fluidic materials into thesystem to displace the expanded casing section adjustable expansion coneassembly upwardly through the expandable wellbore casing to radiallyexpand and plastically deform the expandable wellbore casing.

FIG. 8 is a fragmentary cross-sectional illustration of the system ofFIG. 7 during the subsequent injection of fluidic materials into thesystem to displace the expanded casing section adjustable expansion coneassembly upwardly through the expandable wellbore casing and asurrounding preexisting wellbore casing to radially expand andplastically deform the overlapping expandable wellbore casing and thesurrounding preexisting wellbore casing.

FIG. 9 is a fragmentary cross-sectional illustration of the system ofFIG. 8 during the subsequent operation of the casing cutter to cut offan end of the expandable wellbore casing.

FIG. 10 is a fragmentary cross-sectional illustration of the system ofFIG. 9 during the subsequent removal of the cut off end of theexpandable wellbore casing.

FIGS. 11-1 and 11-2, 11A1 to 11A2, 11B1 to 11B2, 11C, 11D, 11E, 11F,11G, 11H, 11I, 11 j, and 11K are fragmentary cross-sectional andperspective illustrations of an exemplary embodiment of a casing cutterassembly.

FIG. 11L are fragmentary cross-sectional illustrations of an exemplaryembodiment of the operation of the casing cutter assembly of FIGS. 11-1and 11-2, 11A1 to 11A2, 11B1 to 11B2, 11C, 11D, 11E, 11F, 11G, 11H, 11I,11J, and 11K.

FIGS. 12A1 to 12A4 and 12C1 to 12C4 are fragmentary cross-sectionalillustrations of an exemplary embodiment of a ball gripper assembly.

FIG. 12B is a top view of a portion of the ball gripper assembly ofFIGS. 12A1 to 12A4 and 12C1 to 12C4.

FIGS. 13A1 to 13A8 and 13B1 to 13B7 are fragmentary cross-sectionalillustrations of an exemplary embodiment of a tension actuator assembly.

FIGS. 14A to 14C is a fragmentary cross-sectional illustration of anexemplary embodiment of a packer setting tool assembly.

FIGS. 15-1 to 15-5 is a fragmentary cross-sectional illustration of anexemplary embodiment of a packer assembly.

FIGS. 16A1 to 16A5, 16B1 to 16B5, 16C1 to 16C5, 16D1 to 16D5, 16E1 to16E6, 16F1 to 16F6, 16G1 to 16G6, and 16H1 to 16H5, are fragmentarycross-sectional illustrations of an exemplary embodiment of theoperation of the packer setting tool and the packer assembly of FIGS.14A to 14C and 15-1 to 15-5.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring initially to FIGS. 1-10, an exemplary embodiment of a system10 for radially expanding and plastically deforming a wellbore casingincludes a conventional tubular support 12 having an end that is coupledto an end of a casing cutter assembly 14. In an exemplary embodiment,the casing cutter assembly 14 may be, or may include elements, of one ormore conventional commercially available casing cutters for cuttingwellbore casing, or equivalents thereof.

An end of a ball gripper assembly 16 is coupled to another end of thecasing cutter assembly 14. In an exemplary embodiment, the ball gripperassembly 14 may be, or may include elements, of one or more conventionalcommercially available ball grippers, or other types of grippingdevices, for gripping wellbore casing, or equivalents thereof.

An end of a tension actuator assembly 18 is coupled to another end ofthe ball gripper assembly 16. In an exemplary embodiment, the tensionactuator assembly 18 may be, or may include elements, of one or moreconventional commercially actuators, or equivalents thereof.

An end of a safety sub assembly 20 is coupled to another end of thetension actuator assembly 18. In an exemplary embodiment, the safety subassembly 20 may be, or may include elements, of one or more conventionalapparatus that provide quick connection and/or disconnection of tubularmembers, or equivalents thereof.

An end of a sealing cup assembly 22 is coupled to another end of thesafety sub assembly 20. In an exemplary embodiment, the sealing cupassembly 22 may be, or may include elements, of one or more conventionalsealing cup assemblies, or other types of sealing assemblies, thatsealingly engage the interior surfaces of surrounding tubular members,or equivalents thereof.

An end of a casing lock assembly 24 is coupled to another end of thesealing cup assembly 22. In an exemplary embodiment, the casing lockassembly 24 may be, or may include elements, of one or more conventionalcasing lock assemblies that lock the position of wellbore casing, orequivalents thereof.

An end of an extension actuator assembly 26 is coupled to another end ofthe casing lock assembly 24. In an exemplary embodiment, the extensionactuator assembly 26 may be, or may include elements, of one or moreconventional actuators, or equivalents thereof.

An end of an adjustable bell section expansion cone assembly 28 iscoupled to another end of the extension actuator assembly 26. In anexemplary embodiment, the adjustable bell section expansion coneassembly 28 may be, or may include elements, of one or more conventionaladjustable expansion devices for radially expanding and plasticallydeforming wellbore casing, or equivalents thereof.

An end of an adjustable casing expansion cone assembly 30 is coupled toanother end of the adjustable bell section expansion cone assembly 28.In an exemplary embodiment, the adjustable casing expansion coneassembly 30 may be, or may include elements, of one or more conventionaladjustable expansion devices for radially expanding and plasticallydeforming wellbore casing, or equivalents thereof.

An end of a packer setting tool assembly 32 is coupled to another end ofthe adjustable casing expansion cone assembly 30. In an exemplaryembodiment, the packer setting tool assembly 32 may be, or may includeelements, of one or more conventional adjustable expansion devices forcontrolling the operation of a conventional packer, or equivalentsthereof.

An end of a stinger assembly 34 is coupled to another end of the packersetting tool assembly 32. In an exemplary embodiment, the stingerassembly 34 may be, or may include elements, of one or more conventionaldevices for engaging a conventional packer, or equivalents thereof.

An end of a packer assembly 36 is coupled to another end of the stingerassembly 34. In an exemplary embodiment, the packer assembly 36 may be,or may include elements, of one or more conventional packers.

As illustrated in FIG. 1, in an exemplary embodiment, during operationof the system 10, an expandable wellbore casing 100 is coupled to andsupported by the casing lock assembly 24 of the system. The system 10 isthen positioned within a wellbore 102 that traverses a subterraneanformation 104 and includes a preexisting wellbore casing 106.

As illustrated in FIG. 2, in an exemplary embodiment, the extensionactuator assembly 26 is then operated to move the adjustable bellsection expansion cone assembly 28, adjustable casing expansion coneassembly 30, packer setting tool assembly 32, stinger assembly 34,packer assembly 36 downwardly in a direction 108 and out of an end ofthe expandable wellbore casing 100. After the adjustable bell sectionexpansion cone assembly 28 and adjustable casing expansion cone assembly30 have been moved to a position out of the end of the expandablewellbore casing 100, the adjustable bell section expansion cone assemblyand adjustable casing expansion cone assembly are then operated toincrease the outside diameters of the expansion cone assemblies. In anexemplary embodiment, the increased outside diameter of the adjustablebell section expansion cone assembly 28 is greater than the increasedoutside diameter of the adjustable casing expansion cone assembly 30.

As illustrated in FIG. 3, in an exemplary embodiment, the ball gripperassembly 16 is then operated to engage and hold the position of theexpandable tubular member 100 stationary relative to the tubular supportmember 12. The tension actuator assembly 18 is then operated to move theadjustable bell section expansion cone assembly 28, adjustable casingexpansion cone assembly 30, packer setting tool assembly 32, stingerassembly 34, packer assembly 36 upwardly in a direction 110 into andthrough the end of the expandable wellbore casing 100. As a result, theend of the expandable wellbore casing 100 is radially expanded andplastically deformed by the adjustable bell section expansion coneassembly 28 to form a bell section 112. In an exemplary embodiment,during the operation of the system 10 described above with reference toFIG. 3, the casing lock assembly 24 may or may not be coupled to theexpandable wellbore casing 100.

In an exemplary embodiment, the length of the end of the expandablewellbore casing 100 that is radially expanded and plastically deformedby the adjustable bell section expansion cone assembly 28 is limited bythe stroke length of the tension actuator assembly 18. In an exemplaryembodiment, once the tension actuator assembly 18 completes a stroke,the ball gripper assembly 16 is operated to release the expandabletubular member 100, and the tubular support 12 is moved upwardly topermit the tension actuator assembly to be re-set. In this manner, thelength of the bell section 112 can be further extended by continuing tostroke and then re-set the position of the tension actuator assembly 18.Note, that, during the upward movement of the tubular support 12 tore-set the position of the tension actuator assembly 18, the expandabletubular wellbore casing 100 is supported by the expansion surfaces ofthe adjustable bell section expansion cone assembly 28.

As illustrated in FIG. 4, in an exemplary embodiment, the casing lockassembly 24 is then operated to engage and maintain the position of theexpandable wellbore casing 100 stationary relative to the tubularsupport 12. The adjustable bell section expansion cone assembly 28,adjustable casing expansion cone assembly 30, packer setting toolassembly 32, stinger assembly 34, and packer assembly 36 are displaceddownwardly into the bell section 112 in a direction 114 relative to theexpandable wellbore casing 100 by operating the extension actuator 26and/or by displacing the system 10 downwardly in the direction 114relative to the expandable wellbore casing. After the adjustable bellsection expansion cone assembly 28 and adjustable casing expansion coneassembly 30 have been moved downwardly in the direction 114 into thebell section 112 of the expandable wellbore casing 100, the adjustablebell section expansion cone assembly is then operated to decrease theoutside diameter of the adjustable bell section expansion cone assembly.In an exemplary embodiment, the decreased outside diameter of theadjustable bell section expansion cone assembly 28 is less than theincreased outside diameter of the adjustable casing expansion coneassembly 30. In an exemplary embodiment, during the operation of thesystem illustrated and described above with reference to FIG. 4, theball gripper 16 may or may not be operated to engage the expandablewellbore casing 100.

As illustrated in FIG. 5, in an exemplary embodiment, the casing lockassembly 24 is then disengaged from the expandable wellbore casing 100and fluidic material 116 is then injected into the system 10 through thetubular support 12 to thereby pressurize an annulus 118 defined withinthe expandable wellbore casing below the cup sub assembly 22. As aresult, a pressure differential is created across the cup seal assembly22 that causes the cup seal assembly to apply a tensile force in thedirection 120 to the system 10. As a result, the system 10 is displacedupwardly in the direction 120 relative to the expandable wellbore casing100 thereby pulling the adjustable casing expansion cone assembly 30upwardly in the direction 120 through the expandable wellbore casingthereby radially expanding and plastically deforming the expandablewellbore casing.

In an exemplary embodiment, the tension actuator assembly 16 may also beoperated during the injection of the fluidic material 116 to displacethe adjustable casing expansion cone assembly 30 upwardly relative tothe tubular support 12. As a result, additional expansion forces may beapplied to the expandable wellbore casing 100.

As illustrated in FIG. 6, in an exemplary embodiment, the radialexpansion and plastic deformation of the expandable wellbore casingusing the adjustable casing expansion cone assembly 30 continues untilthe packer assembly 36 is positioned within a portion of the expandabletubular member above the bell section 112. The packer assembly 36 maythen be operated to engage the interior surface of the expandablewellbore casing 100 above the bell section 112.

In an exemplary embodiment, after the packer assembly 36 is operated toengage the interior surface of the expandable wellbore casing 100 abovethe bell section 112, a hardenable fluidic sealing material 122 may thenbe injected into the system 10 through the tubular support 12 and thenout of the system through the packer assembly to thereby permit theannulus between the expandable wellbore casing and the wellbore 102 tobe filled with the hardenable fluidic sealing material. The hardenablefluidic sealing material 122 may then be allowed to cure to form a fluidtight annulus between the expandable wellbore casing 100 and thewellbore 102, before, during, or after the completion of the radialexpansion and plastic deformation of the expandable wellbore casing.

As illustrated in FIG. 7, in an exemplary embodiment, the fluidicmaterial 116 is then re-injected into the system 10 through the tubularsupport 12 to thereby re-pressurize the annulus 118 defined within theexpandable wellbore casing below the cup sub assembly 22. As a result, apressure differential is once again created across the cup seal assembly22 that causes the cup seal assembly to once again apply a tensile forcein the direction 120 to the system 10. As a result, the system 10 isdisplaced upwardly in the direction 120 relative to the expandablewellbore casing 100 thereby pulling the adjustable casing expansion coneassembly 30 upwardly in the direction 120 through the expandablewellbore casing thereby radially expanding and plastically deforming theexpandable wellbore casing and disengaging the stinger assembly 34 fromthe packer assembly 36. In an exemplary embodiment, during thisoperational mode, the packer assembly 36 prevents the flow of fluidicmaterials out of the expandable wellbore casing 100. As a result, thepressurization of the annulus 118 is rapid and efficient therebyenhancing the operational efficiency of the subsequent radial expansionand plastic deformation of the expandable wellbore casing 100.

In an exemplary embodiment, the tension actuator assembly 16 may also beoperated during the re-injection of the fluidic material 116 to displacethe adjustable casing expansion cone assembly 30 upwardly relative tothe tubular support 12. As a result, additional expansion forces may beapplied to the expandable wellbore casing 100.

As illustrated in FIG. 8, in an exemplary embodiment, the radialexpansion and plastic deformation of the expandable wellbore casingusing the adjustable casing expansion cone assembly 30 continues untilthe adjustable casing expansion cone assembly 30 reaches the portion 124of the expandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106. At which point, the system 10 may radially expandthe portion 124 of the expandable wellbore casing 100 that overlaps withthe preexisting wellbore casing 106 and the surrounding portion of thepreexisting wellbore casing. Consequently, in an exemplary embodiment,during the radial expansion of the portion 124 of the expandablewellbore casing 100 that overlaps with the preexisting wellbore casing106, the tension actuator assembly 16 is also operated to displace theadjustable casing expansion cone assembly 30 upwardly relative to thetubular support 12. As a result, additional expansion forces may beapplied to the expandable wellbore casing 100 and the preexistingwellbore casing 106 during the radial expansion of the portion 124 ofthe expandable wellbore casing that overlaps with the preexistingwellbore casing.

As illustrated in FIG. 9, in an exemplary embodiment, the entire lengthof the portion 124 of the expandable wellbore casing 100 that overlapswith the preexisting wellbore casing 106 is not radially expanded andplastically deformed. Rather, only part of the portion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106 is radially expanded and plastically deformed. Theremaining part of the portion 124 of the expandable wellbore casing 100that overlaps with the preexisting wellbore casing 106 is then cut awayby operating the casing cutter assembly 14.

As illustrated in FIG. 10, the remaining part of the portion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106 that is cut away by operating the casing cutterassembly 14 is then also carried out of the wellbore 102 using thecasing cutter assembly.

Furthermore, in an exemplary embodiment, the inside diameter of theexpandable wellbore casing 100 above the bell section 112 is equal tothe inside diameter of the portion of the preexisting wellbore casing106 that does not overlap with the expandable wellbore casing 100. As aresult, a wellbore casing is constructed that includes overlappingwellbore casings that together define an internal passage having aconstant cross-sectional area.

In several exemplary embodiments, the system 10 includes one or more ofthe methods and apparatus disclosed in one or more of the following: (1)U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser.No. 09/454,139, filed on Dec. 3, 1999, which claims priority fromprovisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, whichclaims priority from provisional application 60/121,702, filed on Feb.25, 1999, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb.10, 2000, which claims priority from provisional application 60/119,611,filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed asU.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999,which claims priority from provisional application 60/108,558, filed onNov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, filed onJul. 1, 2002, which claims priority from provisional application60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application Ser. No.09/523,468, filed on Mar. 10, 2000, which claims priority fromprovisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S.Pat. No. 6,568,471, which was filed as patent application Ser. No.09/512,895, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S.Pat. No. 6,575,240, which was filed as patent application Ser. No.09/511,941, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S.Pat. No. 6,557,640, which was filed as patent application Ser. No.09/588,946, filed on Jun. 7, 2000, which claims priority fromprovisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S.patent application Ser. No. 09/981,916, filed on Oct. 18, 2001 as acontinuation-in-part application of U.S. Pat. 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In an exemplary embodiment, the casing cutter assembly 14 is providedand operates substantially, at least in part, as disclosed in PCT patentapplication Ser. No. PCT/US03/29858, filed on Sep. 22, 2003, thedisclosure of which is incorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 11-1 and 11-2, 11A1to 11A2, 11B1 to 11B2, 11C, 11D, 11E, 11F, 11G, 11H, 11I, 11J, and 11K,the casing cutter assembly 14 includes an upper tubular tool joint 11002that defines a longitudinal passage 11002 a and mounting holes, 11002 band 11002 c, and includes an internal threaded connection 11002 d, aninner annular recess 11002 e, an inner annular recess 11002 f, and aninternal threaded connection 11002 g. A tubular torque plate 11004 thatdefines a longitudinal passage 11004 a and includes circumferentiallyspaced apart teeth 11004 b is received within, mates with, and iscoupled to the internal annular recess 11002 e of the upper tubular tooljoint 11002.

Circumferentially spaced apart teeth 11006 a of an end of a tubularlower mandrel 11006 that defines a longitudinal passage 11006 b, aradial passage 11006 ba, and a radial passage 11006 bb and includes anexternal threaded connection 11006 c, an external flange 11006 d, anexternal annular recess 11006 e having a step 11006 f at one end, anexternal annular recess 11006 g, external teeth 11006 h, an externalthreaded connection 11006 i, and an external annular recess 11006 jengage the circumferentially spaced apart teeth 11004 b of the tubulartorque plate 11004. An internal threaded connection 11008 a of an end ofa tubular toggle bushing 11008 that defines a longitudinal passage 11008b, an upper longitudinal slot 11008 c, a lower longitudinal slot 11008d, mounting holes, 11008 e, 11008 f, 11008 g, 11008 h, 11008 i, 11008 j,11008 k, 11008 l, 11008 m, 11008 n, 11008 o, 11008 p, 11008 q, 11008 r,11008 s, 11008 t, 11008 u, 11008 v, 11008 w, 11008 x, 11008 xa, and11008 xb, and includes an external annular recess 11008 y, internalannular recess 11008 z, external annular recess 11008 aa, and anexternal annular recess 11008 ab receives and is coupled to the externalthreaded connection 11006 c of the tubular lower mandrel 11006.

A sealing element 11010 is received within the external annular recess11008 y of the tubular toggle bushing 11008 for sealing the interfacebetween the tubular toggle bushing and the upper tubular tool joint11002. A sealing element 11012 is received within the internal annularrecess 11008 z of the tubular toggle bushing 11008 for sealing theinterface between the tubular toggle bushing and the tubular lowermandrel 11006.

Mounting screws, 11014 a and 11014 b, mounted within and coupled to themounting holes, 11008 w and 11008 x, respectively, of the tubular togglebushing 11008 are also received within the mounting holes, 11002 b and11002 c, of the upper tubular tool joint 11002. Mounting pins, 11016 a,11016 b, 11016 c, 11016 d, and 11016 e, are mounted within the mountingholes, 11008 e, 11008 f, 11008 g, 11008 h, and 11008 i, respectively.Mounting pins, 11018 a, 11018 b, 11018 c, 11018 d, and 11018 e, aremounted within the mounting holes, 11008 t, 11008 s, 11008 r, 11008 q,and 11008 p, respectively. Mounting screws, 11020 a and 11020 b, aremounted within the mounting holes, 11008 u and 11008 v, respectively.

A first upper toggle link 11022 defines mounting holes, 11022 a and11022 b, for receiving the mounting pins, 11016 a and 11016 b, andincludes a mounting pin 11022 c at one end. A first lower toggle link11024 defines mounting holes, 11024 a, 11024 b, and 11024 c, forreceiving the mounting pins, 11022 c, 11016 c, and 11016 d, respectivelyand includes an engagement arm 11024 d. A first trigger 11026 defines amounting hole 11026 a for receiving the mounting pin 11016 e andincludes an engagement arm 11026 b at one end, an engagement member11026 c, and an engagement arm 11026 d at another end.

A second upper toggle link 11028 defines mounting holes, 11028 a and11028 b, for receiving the mounting pins, 11018 a and 11018 b, andincludes a mounting pin 11028 c at one end. A second lower toggle link11030 defines mounting holes, 11030 a, 11030 b, and 11030 c, forreceiving the mounting pins, 11028 c, 11018 c, and 11018 d, respectivelyand includes an engagement arm 11030 d. A second trigger 11032 defines amounting hole 11032 a for receiving the mounting pin 11018 e andincludes an engagement arm 11032 b at one end, an engagement member11032 c, and an engagement arm 11032 d at another end.

An end of a tubular spring housing 11034 that defines a longitudinalpassage 11034 a, mounting holes, 11034 b and 11034 c, and mountingholes, 11034 ba and 11034 ca, and includes an internal flange 11034 dand an internal annular recess 11034 e at one end, and an internalflange 11034 f, an internal annular recess 11034 g, an internal annularrecess 11034 h, and an external threaded connection 11034 i at anotherend receives and mates with the end of the tubular toggle bushing 11008.Mounting screws, 11035 a and 11035 b, are mounted within and coupled tothe mounting holes, 11008 xb and 11008 xa, respectively, of the tubulartoggle bushing 11008 and are received within the mounting holes, 11034ba and 11034 ca, respectively, of the tubular spring housing 11034.

A tubular retracting spring ring 11036 that defines mounting holes,11036 a and 11036 b, receives and mates with a portion of the tubularlower mandrel 11006 and is received within and mates with a portion ofthe tubular spring housing 11034. Mounting screws, 11038 a and 11038 b,are mounted within and coupled to the mounting holes, 11036 a and 11036b, respectively, of the tubular retracting spring ring 11036 and extendinto the mounting holes, 11034 b and 11034 c, respectively, of thetubular spring housing 11034.

Casing diameter sensor springs, 11040 a and 11040 b, are positionedwithin the longitudinal slots, 11008 c and 1108 d, respectively, of thetubular toggle bushing 11008 that engage the engagement members, 11026 cand 11032 c, and engagement arms, 11026 d and 11032 d, of the first andsecond triggers, 11026 and 11032, respectively. An inner flange 11042 aof an end of a tubular spring washer 11042 mates with and receives aportion of the tubular lower mandrel 11006 and an end face of the innerflange of the tubular spring washer is positioned proximate and end faceof the external flange 11006 d of the tubular lower mandrel. The tubularspring washer 11042 is further received within the longitudinal passage11034 a of the tubular spring housing 11034.

An end of a retracting spring 11044 that receives the tubular lowermandrel 11006 is positioned within the tubular spring washer 11042 incontact with the internal flange 11042 a of the tubular spring washerand the other end of the retracting spring is positioned in contact withan end face of the tubular retracting spring ring 11036.

A sealing element 11046 is received within the external annular recess11006 j of the tubular lower mandrel 11006 for sealing the interfacebetween the tubular lower mandrel and the tubular spring housing 11034.A sealing element 11048 is received within the internal annular recess11034 h of the tubular spring housing 11034 for sealing the interfacebetween the tubular spring housing and the tubular lower mandrel 11006.

An internal threaded connection 11050 a of an end of a tubular upperhinge sleeve 11050 that includes an internal flange 11050 b and aninternal pivot 11050 c receives and is coupled to the external threadedconnection 11034 i of the end of the tubular spring housing 11034.

An external flange 11052 a of a base member 11052 b of an upper camassembly 11052, that is mounted upon and receives the lower tubularmandrel 11006, that includes an internal flange 11052 c that is receivedwithin the external annular recess 11006 e of the lower tubular mandrel11006 and a plurality of circumferentially spaced apart cam arms 11052 dextending from the base member mates with and is received within thetubular upper hinge sleeve 11050. An end face of the base member 11052 bof the upper cam assembly 11052 is coupled to an end face of the tubularspring housing 11034 and an end face of the external flange 11052 a ofthe base member of the upper cam assembly 11052 is positioned inopposing relation to an end face of the internal flange 11050 b of thetubular upper hinge sleeve 11050. Each of the cam arms 11052 d of theupper cam assembly 11052 include external cam surfaces 11052 e. In anexemplary embodiment, the base member 11052 b of the upper cam assembly11052 further includes axial teeth for interleaving with and engagingaxial teeth provided on the end face of the tubular spring housing 11034for transmitting torsional loads between the tubular spring housing andthe upper cam assembly.

A plurality of circumferentially spaced apart upper casing cuttersegments 11054 are mounted upon and receive the lower tubular mandrel11006 and each include an external pivot recess 11054 a for mating withand receiving the internal pivot 11050 c of the tubular upper hingesleeve 11050 and an external flange 11054 b and are pivotally mountedwithin the tubular upper hinge sleeve and are interleaved with thecircumferentially spaced apart cam arms 11052 d of the upper camassembly 11052. A casing cutter element 11056 is coupled to andsupported by the upper surface of each upper casing cutter segments11054 proximate the external flange 11054 b.

A plurality of circumferentially spaced apart lower casing cuttersegments 11058 are mounted upon and receive the lower tubular mandrel11006, are interleaved among the upper casing cutter segments 11054, aresubstantially identical to the upper casing cutter segments, and areoriented in the opposite direction to the upper casing cutter segments.

A lower cam assembly 11060 is mounted upon and receives the lowertubular mandrel 11006 that includes circumferentially spaced apart camarms interleaved among the lower casing cutter segments 11058 issubstantially identical to the upper cam assembly 11052 with theaddition of mounting holes, 11060 a, 11060 b, 11060 c, and 11060 d. Inan exemplary embodiment, the base member of the lower cam assembly 11060further includes axial teeth for interleaving with and engaging axialteeth provided on the end face of the tubular sleeve 11066 fortransmitting torsional loads between the tubular spring housing and thetubular sleeve.

Mounting screws, 11062 a, 11062 b, 11062 c, and 11062 e, are mountedwithin the mounting holes, 11060 a, 11060 b, 11060 c, and 11060 d,respectively, of the lower cam assembly 11060 and are received withinthe external annular recess 11006 g of the lower cam assembly 11060.

A tubular lower hinge sleeve 11064 that receives the lower casing cuttersegments 11058 and the lower cam assembly 11060 includes an internalflange 11064 a for engaging the external flange of the base member ofthe lower cam assembly 11060, an internal pivot 11064 b for pivotallymounting the lower casing cutter segments within the tubular lower hingesleeve, and an internal threaded connection 11064 c.

An external threaded connection 11066 a of an end of a tubular sleeve11066 that defines mounting holes, 11066 b and 11066 c, and includes aninternal annular recess 11066 d having a shoulder 11066 e, an internalflange 11066 f, and an internal threaded connection 11066 g at anotherend is received within and coupled to the internal threaded connection11064 c of the tubular lower hinge sleeve 11064. An external threadedconnection 11068 a of an end of a tubular member 11068 that defines alongitudinal passage 11068 b and mounting holes, 11068 c and 11068 d,and includes an external annular recess 11068 e, and an externalthreaded connection 11068 f at another end is received within and iscoupled to the internal threaded connection 11066 g of the tubularsleeve 11066.

Mounting screws, 11070 a and 11070 b, are mounted in and coupled to themounting holes, 11068 c and 11068 d, respectively, of the tubular member11068 that also extend into the mounting holes, 11066 b and 11066 c,respectively, of the tubular sleeve 11066. A sealing element 11072 isreceived within the external annular recess 11068 e of the tubularmember 11068 for sealing the interface between the tubular member andthe tubular sleeve 11066.

An internal threaded connection 11074 a of a tubular retracting piston11074 that defines a longitudinal passage 11074 b and includes aninternal annular recess 11074 c and an external annular recess 11074 dreceives and is coupled to the external threaded connection 11006 i ofthe tubular lower mandrel 11006. A sealing element 11076 is receivedwithin the external annular recess 11074 d of the tubular retractingpiston 11074 for sealing the interface between the tubular retractingpiston and the tubular sleeve 11066. A sealing element 11078 is receivedwithin the internal annular recess 11074 c of the tubular retractingpiston 11074 for sealing the interface between the tubular retractingpiston and the tubular lower mandrel 11006.

Locking dogs 11080 mate with and receive the external teeth 11006 h ofthe tubular lower mandrel 11006. A spacer ring 11082 is positionedbetween an end face of the locking dogs 11080 and an end face of thelower cam assembly 11060. A release piston 11084 mounted upon thetubular lower mandrel 11006 defines a radial passage 11084 a formounting a burst disk 11086 includes sealing elements, 11084 b, 11084 c,and 11084 d. The sealing elements, 11084 b and 11084 d, sealing theinterface between the release piston 11084 and the tubular lower mandrel11006. An end face of the release piston 11084 is positioned in opposingrelation to an end face of the locking dogs 11080.

A release sleeve 11088 that receives and is mounted upon the lockingdogs 11080 and the release piston 11084 includes an internal flange11088 a at one end that sealingly engages the tubular lower mandrel11006. A bypass sleeve 11090 that receives and is mounted upon therelease sleeve 11088 includes an internal flange 11090 a at one end.

In an exemplary embodiment, during operation of the casing cutterassembly 14, the retracting spring 11044 is compressed and therebyapplies a biasing spring force in a direction 11092 from the lowertubular mandrel 11006 to the tubular spring housing 11034 that, in theabsence of other forces, moves and/or maintains the upper cam assembly11052 and the upper casing cutter segments 11054 out of engagement withthe lower casing cutter segments 11058 and the lower cam assembly 11060.In an exemplary embodiment, during operation of the casing cutterassembly 14, an external threaded connection 12A1 to 12A4 of an end ofthe tubular support member 12 is coupled to the internal threadedconnection 11002 d of the upper tubular tool joint 11002 and an internalthreaded connection 16 a of an end of the ball gripper assembly 16 iscoupled to the external threaded connection 11068 f of the tubularmember 11068.

The upper cam assembly 11052 and the upper casing cutter segments 11054may be brought into engagement with the lower casing cutter segments11058 and the lower cam assembly 11060 by pressurizing an annulus 11094defined between the lower tubular mandrel 11006 and the tubular springhousing 11034. In particular, injection of fluid materials into the camcutter assembly 14 through the longitudinal passage 11006 b of the lowertubular mandrel 11006 and into the radial passage 11006 ba maypressurize the annulus 11094 thereby creating sufficient operatingpressure to generate a force in a direction 11096 sufficient to overcomethe biasing force of the retracting spring 11044. As a result, thespring housing 11034 may be displaced in the direction 11096 relative tothe lower tubular mandrel 11006 thereby displacing the tubular upperhinge sleeve 11050, upper cam assembly 11052, and upper casing cuttersegments 11054 in the direction 11096.

In an exemplary embodiment, as illustrated in FIG. 11L, the displacementof the upper cam assembly 11052 and upper casing cutter segments 11054in the direction 11096 will cause the lower casing cutter segments 11058to ride up the cam surfaces of the cam arms of the upper cam assembly11052 while also pivoting about the lower tubular hinge segment 11064,and will also cause the upper casing cutter segments 11054 to ride upthe cam surfaces of the cam arms of the lower cam assembly 11060 whilealso pivoting about the upper tubular hinge segment 11050.

In an exemplary embodiment, during the operation of the casing cutterassembly 14, when the upper and lower casing cutter segments, 11054 and11058, brought into axial alignment in a radially expanded position, thecasing cutter elements of the casing cutter segments are brought intointimate contact with the interior surface of a preselected portion ofthe expandable wellbore casing 100. The casing cutter assembly 14 maythen be rotated to thereby cause the casing cutter elements to cutthrough the expandable wellbore casing. The portion of the expandablewellbore casing 100 cut away from the remaining portion on theexpandable wellbore casing may then be carried out of the wellbore 102with the cut away portion of the expandable wellbore casing supported bythe casing cutter elements.

In an exemplary embodiment, the upper cam assembly 11052 and the uppercasing cutter segments 11054 may be moved out of engagement with thelower casing cutter segments 11058 and the lower cam assembly 11060 byreducing the operating pressure within the annulus 11094.

In an alternative embodiment, during operation of the casing cutterassembly 14, the upper cam assembly 11052 and the upper casing cuttersegments 11054 may also be moved out of engagement with the lower casingcutter segments 11058 and the lower cam assembly 11060 by sensing theoperating pressure within the longitudinal passage 11006 b of the lowertubular mandrel 11006. In particular, if the operating pressure withinthe longitudinal passage 11006 b of the lower tubular mandrel 11006exceeds a predetermined value, the burst disc 11086 will open therebypressurizing the interior of the tubular release sleeve 11088 therebydisplacing the tubular release sleeve downwardly away from engagementwith the locking dogs 11080. As a result, the locking dogs 11080 arereleased from engagement with the lower tubular mandrel 11006 therebypermitting the lower casing cutter segments 11058 and the lower camassembly 11060 to be displaced downwardly relative to the lower tubularmandrel. The retracting piston 11074 may then be displaced downwardly bythe operating pressure thereby impacting the internal flange 11066 f ofthe lower tubular mandrel 11066. As a result, the lower tubular mandrel11066, the lower casing cutter segments 11058, the lower cam assembly11060, and tubular lower hinge sleeve 11064 are displaced downwardlyrelative to the tubular spring housing 11034 thereby moving the lowercasing cutter segments 11058 and the lower cam assembly 11060 out ofengagement with the upper cam assembly 11052 and the upper casing cuttersegments 11054.

In an exemplary embodiment, during operation of the casing cutterassembly 14, the casing cutter assembly 14 senses the diameter of theexpandable wellbore casing 100 using the upper toggle links, 11022 and11028, lower toggle links, 11024 and 11030, and triggers, 11026 and11032, and then prevents the engagement of the upper cam assembly 11052and the upper casing cutter segments 11054 with the lower casing cuttersegments 11058 and the lower cam assembly 11060. In particular, anytimethe upper toggle links, 11022 and 11028, and lower toggle links, 11024and 11030, are positioned within a portion of the expandable wellborecasing 100 that has not been radially expanded and plastically deformedby the system 10, the triggers, 11026 and 11032, will be maintained in aposition in which the triggers will engage the internal flange 11034 dof the end of the tubular spring housing 11034 thereby preventing thedisplacement of the tubular spring housing in the direction 11096. As aresult, the upper cam assembly 11052 and the upper casing cuttersegments 11054 cannot be brought into engagement with the lower casingcutter segments 11058 and the lower cam assembly 11060.

Conversely, anytime the upper toggle links, 11022 and 11028, and lowertoggle links, 11024 and 11030, are positioned within a portion of theexpandable wellbore casing 100 that has been radially expanded andplastically deformed by the system 10, the triggers, 11026 and 11032,will be pivoted by the engagement arms, 11024 d and 11030 d, of thelower toggle links, 11024 and 11030, to a position in which the triggerswill no longer engage the internal flange 11034 d of the end of thetubular spring housing 11034 thereby permitting the displacement of thetubular spring housing in the direction 11096. As a result, the uppercam assembly 11052 and the upper casing cutter segments 11054 can bebrought into engagement with the lower casing cutter segments 11058 andthe lower cam assembly 11060.

In an alternative embodiment, the elements of the casing cutter assembly14 that sense the diameter of the expandable wellbore casing 100 may bedisabled or omitted.

In an exemplary embodiment, the ball gripper assembly 16 is provided andoperates substantially, at least in part, as disclosed in one or more ofthe following: (1) PCT patent application Ser. No. PCT/US03/29859, filedon Sep. 22, 2003, and/or (2) PCT patent application Ser. No.PCT/US03/14153, filed on Nov. 13, 2003, the disclosures of which areincorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 12A1 to 12A4, 12Band 12C1 to 12C4, the ball gripper assembly 16 includes an upper mandrel1202 that defines a longitudinal passage 1202 a and a radial passage1202 b and includes an internal threaded connection 1202 c at one end,an external flange 1202 d at an intermediate portion that includes anexternal annular recess 1202 e having a shoulder 1202 f and an externalradial hole 1202 g, an external annular recess 1202 h, an externalannular recess 1202 i, an external annular recess 1202 j having atapered end 1202 k including an external annular recess 1202 ka, anexternal annular recess 12021, and an external annular recess 1202 m,and an external annular recess 1202 n, an external radial hole 1202 o,an external annular recess 1202 p, and an external annular recess 1202 qat another end.

An upper tubular bushing 1204 defines an internally threaded radialopening 1204 a and includes an external flange 1204 b having an externalannular recess 1204 c and an internal annular recess 1204 d mates withand receives the external flange 1202 d of the upper mandrel 1202. Inparticular, the internal annular recess 1204 d of the upper tubularbushing 1204 mates with the shoulder 1202 f of the external annularrecess 1202 e of the upper mandrel 1202. A screw 1206 that is threadablycoupled to the internally threaded radial opening 1204 a of the uppertubular bushing 1204 extends into the external radial hole 1202 g of theexternal flange 1202 d of the upper mandrel 1202.

A deactivation tubular sleeve 1208 defines a radial passage 1208 a andincludes an internal annular recess 1208 b that mates with and receivesan end of the external annular recess 1204 c of the external flange 1204b of the upper tubular bushing 1204, an internal annular recess 1208 cthat mates with and receives the external flange 1202 d of the uppermandrel 1202, an internal annular recess 1208 d, an internal annularrecess 1208 e, and an internal annular recess 1208 f. A deactivationspring 1210 is received within an annulus 1212 defined between theinternal annular recess 1208 b of the deactivation tubular sleeve 1208,an end face of the external annular recess 1204 c of the external flange1204 b of the upper tubular bushing 1204, and the external annularrecess 1202 h of the external flange 1202 d of the upper mandrel 1202.

A sealing member 1214 is received with the external annular recess 1202i of the external flange 1202 d of the upper mandrel 1202 for sealingthe interface between the upper mandrel and the deactivation tubularsleeve 1208. An annular spacer element 1216 is received within theexternal annular recess 1202 ka of the tapered end 1202 k of theexternal annular recess 1202 j of the upper mandrel 1202.

One or more inner engagement elements 1218 a of a tubular coglet 1218engage and are received within the external annular recess 1202 ka ofthe tapered end 1202 k of the external annular recess 1202 j of theupper mandrel 1202 and one or more outer engagement elements 1218 b ofthe coglet engage and are received within the internal annular recess1208 d of the deactivation tubular sleeve 1208.

An external annular recess 1220 a of an end of a tubular coglet prop1220 that includes an inner flange 1220 b receives and mates with theinner surfaces of the outer engagement elements 1218 b of the coglet1218. The end of the tubular coglet prop 1220 further receives and mateswith the external annular recess 1202 j of the external flange 1202 d ofthe upper mandrel 1202. A sealing element 1222 is received within theexternal annular recess 1202 l of the upper mandrel 1202 for sealing theinterface between the upper mandrel and the tubular coglet prop 1220.

An end of a tubular bumper sleeve 1224 that includes internal andexternal flanges, 1224 a and 1224 b, and a hole 1224 c at another endmates with and receives the external annular recess 1202 m of theexternal flange 1202 d of the upper mandrel 1202. A coglet spring 1226is received within an annulus 1228 defined between the external annularrecess 1202 m of the external flange 1202 d of the upper mandrel 1202,the tubular coglet prop 1220, the inner flange 1220 b of the tubularcoglet prop, an end face of the tubular bumper sleeve 1224, and theinternal annular recess 1208 c of the deactivation tubular sleeve 1208.

A tubular ball race 1228 that defines a plurality of tapered annularrecesses 1228 a and an internally threaded radial opening 1228 b andincludes one or more axial engagement elements 1228 c at one end and oneor more axial engagement elements 1228 d at another end receives andmates with the other end of the upper mandrel 1202. In an exemplaryembodiment, the axial engagement elements 1228 c of the tubular ballrace 1228 are received within and are coupled to the hole 1224 c of thetubular bumper sleeve 1224. An end of a tubular activation sleeve 1230that defines a plurality of radial openings 1230 a, a radial opening1230 b, a radial opening 1230 c, and includes an internal annular recess1230 d receives and mates with the tubular ball race 1228. In anexemplary embodiment, an end face of an end of the tubular activationsleeve 1230 is positioned proximate and in opposing relation to an endface of an end of the deactivation sleeve 1208. In an exemplaryembodiment, the radial openings 1230 a are aligned with and positionedin opposing relation to corresponding of tapered annular recesses 1228 aof the tubular ball race 1228, and the radial openings are also narrowedin cross section in the radial direction for reasons to be described.

Balls 1232 are received within each of the of tapered annular recesses1228 a and corresponding radial openings 1230 a of the tubular ball race1228 and tubular activation sleeve 1230, respectively. In an exemplaryembodiment, the narrowed cross sections of the radial openings 1230 a ofthe tubular activation sleeve 1230 will permit the balls 1232 to bedisplaced outwardly in the radial direction until at least a portion ofthe balls extends beyond the outer perimeter of the tubular activationsleeve to thereby permit engagement of the balls with an outer structuresuch as, for example, a wellbore casing.

A lower mandrel 1234 that defines a longitudinal passage 1234 a and aninternally threaded radial passage 1234 b at one end and includesinternal annular recesses, 1234 c and 1234 d, for receiving and matingwith the external annular recesses, 1202 p and 1202 q, of the uppermandrel 1202, an internal annular recess 1234 e, an external flange 1234f, and an externally threaded connection 1234 g at another end. In anexemplary embodiment, as illustrated in FIG. 12B, the end of the lowermandrel 1234 further includes longitudinal recesses 1234 h for receivingand mating with corresponding axial engagement elements 1228 d of thetubular ball race 1228. A sealing element 1235 is received within theinternal annular recess 1234 d of the lower mandrel 1234 for sealing aninterface between the lower mandrel and the external annular recess 1202p of the upper mandrel 1202.

A tubular spring retainer 1236 that defines a radial passage 1236 a andincludes an external annular recess 1236 b at one end mates with andreceives the end of the lower mandrel 1234 and is positioned proximatean end face of the external flange 1234 f of the lower mandrel. Atubular spring retainer 1238 receives and mates with the end of thelower mandrel 1234 and is received and mates with the internal annularrecess 1230 d of the tubular activation sleeve 1230.

An activation spring 1240 is received within an annulus 1242 defined anend face of the tubular spring retainer 1238, an end face of the springretainer 1236, the internal annular recess 1230 d of the tubularactivation sleeve 1230, and the end of the lower mandrel 1234. Aretainer screw 1242 is received within and is threadably coupled to theinternally threaded radial opening 1234 b of the lower mandrel 1234 thatalso extends into the external radial hole 1202 o of the upper mandrel1202.

During operation of the ball gripper assembly 16, in an exemplaryembodiment, as illustrated in FIGS. 12A1 to 12A4, the ball gripperassembly may be positioned within the expandable wellbore casing 100 andthe internally threaded connection 1202 c of the upper mandrel 1202 maybe coupled to an externally threaded connection 14 a of an end of thecasing cutter assembly 14 and the externally threaded connection 1234 gof the lower mandrel 1234 may be coupled to an internally threadedconnection 18 a of an end of the tension actuator assembly 18.

In an alternative embodiment, the internally threaded connection 1202 cof the upper mandrel 1202 may be coupled to an externally threadedconnection of an end of the tension actuator assembly 18 and theexternally threaded connection 1234 g of the lower mandrel 1234 may becoupled to an internally threaded connection of an end of casing cutterassembly 14.

In an exemplary embodiment, the deactivation spring 1210 has a greaterspring rate than the activation spring 1240. As a result, in an initialoperating mode, as illustrated in FIGS. 12A1 to 12A4, a biasing springforce is applied to the deactivation sleeve 1208 and activation sleeve1230 in a direction 1244 that maintains the activation sleeve in aposition relative to the tubular ball race 1228 that maintains the balls1232 within the radially inward portions of the corresponding taperedannular recesses 1228 a of the tubular ball race such that the balls donot extend beyond the perimeter of the activation sleeve to engage theexpandable wellbore casing 100.

As illustrated in FIGS. 12C1 to 12C4, in an exemplary embodiment, theball gripper 16 may be operated to engage the interior surface of theexpandable wellbore casing 100 by injecting a fluidic material 1250 intothe ball gripper assembly through the longitudinal passages 1202 a and1234 aa, of the upper and lower mandrels, 1202 and 1234, respectively.

In particular, when the longitudinal and radial passages, 1202 a and1202 b, respectively, of the upper mandrel 1202 are pressurized by theinjection of the fluidic material 1250, the internal annular recess 1208c of the deactivation tubular sleeve 1208 is pressurized. When theoperating pressure of the fluidic material 1250 within the internalannular recess 1208 c of the deactivation tubular sleeve 1208 issufficient to overcome the biasing spring force of the deactivationspring 1210, the deactivation tubular sleeve is displaced in a direction1252. As a result, the spring force provided by the activation spring1240 then may displace the activation tubular sleeve 1230 in thedirection 1252 thereby moving the balls 1232 on the correspondingtapered annular recesses 1228 a of the tubular ball race 1228 outwardlyin a radial direction into engagement with the interior surface of theexpandable wellbore casing 100. In an exemplary embodiment, theoperating pressure of the fluidic material 1250 sufficient to overcomethe biasing spring force of the deactivation spring 1210 was about 100psi.

In an exemplary embodiment, when the operating pressure of the fluidicmaterial 1250 is reduced, the operating pressure of the fluidic material1250 within the internal annular recess 1208 c of the deactivationtubular sleeve 1208 is no longer sufficient to overcome the biasingspring force of the deactivation spring 1210, and the deactivationtubular sleeve and the activation tubular sleeve 1230 are displaced in adirection opposite to the direction 1252 thereby moving the balls 1232radially inwardly and out of engagement with the interior surface of theexpandable wellbore casing 100.

In an exemplary embodiment, the ball gripper assembly 16 is operated toengage the interior surface of the expandable wellbore casing 100 incombination with the operation of the tension actuator assembly 18 toapply an upward tensile force to one or more elements of the system 10coupled to and positioned below the tension actuator assembly. As aresult, a reaction force comprising a downward tensile force is appliedto the lower mandrel 1234 of the ball gripper assembly 16 in a directionopposite to the direction 1252 during the operation of the tensionactuator assembly 18. Consequently, due to the geometry of the tapered1228 a of the tubular ball race 1228, the balls 1232 are driven up thetapered annular recesses 1228 a of the tubular ball race 1228 withincreased force and the contact force between the balls 1232 and theinterior surface of the expandable wellbore casing 100 is significantlyincreased thereby correspondingly increasing the gripping force andeffect of the ball gripper assembly.

In an exemplary embodiment, the ball gripper assembly 16 may be operatedto radially expand and plastically deform discrete portions of theexpandable wellbore casing 100 by controlling the amount of contactforce applied to the interior surface of the expandable wellbore casingby the balls 1232 of the ball gripper assembly. In an experimental testof an exemplary embodiment of the ball gripper assembly 16, anexpandable wellbore casing was radially expanded and plasticallydeformed. This was an unexpected result.

In an exemplary embodiment, the tension actuator assembly 18 operatesand is provided substantially, at least in part, as disclosed in one ormore of the following: (1) PCT patent application Ser. No.PCT/US02/36267, filed on Nov. 12, 2002, (2) PCT patent application Ser.No. PCT/US03/29859, filed on Sep. 22, 2003, (3) PCT patent applicationSer. No. PCT/US03/14153, filed on Nov. 13, 2003, and/or (4) PCT patentapplication Ser. No. PCT/US03/29460, filed on Sep. 23, 2003, thedisclosures of which are incorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 13A1 to 13A8 and13B1 to 13B7, the tension actuator assembly 18 includes an upper tubularsupport member 13002 that defines a longitudinal passage 13002 a, andexternal internally threaded radial openings, 13002 b and 13002 c, andan external annular recess 13002 d and includes an internally threadedconnection 13002 e at one end and an external flange 13002 f, anexternal annular recess 13002 g having an externally threadedconnection, and an internal annular recess 13002 h having an internallythreaded connection at another end. An end of a tubular actuator barrel13004 that defines radial passages, 13004 a and 13004 b, at one end andradial passages, 13004 c and 13004 d, includes an internally threadedconnection 13004 e at one end that mates with, receives, and isthreadably coupled to the external annular recess 13002 g of the uppertubular support member 13002 and abuts and end face of the externalflange 13002 f of the upper tubular support member and an internallythreaded connection 13004 f at another end.

Torsional locking pins, 13006 a and 13006 b, are coupled to and mountedwithin the external radial mounting holes, 13002 b and 13002 c,respectively, of the upper tubular support member and received withinthe radial passages, 13004 a and 13004 b, of the end of the tubularactuator barrel 13004. The other end of the tubular actuator barrel13004 receives and is threadably coupled to an end of a tubular barrelconnector 13008 that defines an internal annular recess 13008 a,external radial mounting holes, 13008 b and 13008 c, radial passages,13008 d and 13008 e, and external radial mounting holes, 13008 f and13008 g and includes circumferentially spaced apart teeth 13008 h at oneend. A sealing cartridge 13010 is received within and coupled to theinternal annular recess 13008 a of the tubular barrel connector 13008for fluidicly sealing the interface between the tubular barrel connectorand the sealing cartridge. Torsional locking pins, 13012 a and 13012 b,are coupled to and mounted within the external radial mounting holes,13008 b and 13008 c, respectively, of the tubular barrel connector 13008and received within the radial passages, 13004 c and 13004 d, of thetubular actuator barrel 13004.

A tubular member 13014 that defines a longitudinal passage 13014 ahaving one or more internal splines 13014 b at one end andcircumferentially spaced apart teeth 13014 c at another end for engagingthe circumferentially spaced apart teeth 13008 h of the tubular barrelconnector 13008 mates with and is received within the actuator barrel13004 and the one end of the tubular member abuts an end face of theother end of the upper tubular support member 13002 and at another endabuts and end face of the tubular barrel connector 13008. A tubularguide member 13016 that defines a longitudinal passage 13016 a having atapered opening 13016 aa, and radial passages, 13016 b and 13016 c,includes an external flange 13016 d having an externally threadedconnection at one end that is received within and coupled to theinternal annular recess 13002 h of the upper tubular support member13002.

The other end of the tubular barrel connector 13008 is threadablycoupled to and is received within an end of a tubular actuator barrel13018 that defines a longitudinal passage 13018 a, radial passages,13018 b and 13018 c, and radial passages, 13018 d and 13018 e. Torsionallocking pins, 13020 a and 13020 b, are coupled to and mounted within theexternal radial mounting holes, 13008 f and 13008 g, respectively, ofthe tubular barrel connector 13008 and received within the radialpassages, 13018 b and 13018 c, of the tubular actuator barrel 13018. Theother end of the tubular actuator barrel 13018 receives and isthreadably coupled to an end of a tubular barrel connector 13022 thatdefines an internal annular recess 13022 a, external radial mountingholes, 13022 b and 13022 c, radial passages, 13022 d and 13022 e, andexternal radial mounting holes, 13022 f and 13022 g. A sealing cartridge13024 is received within and coupled to the internal annular recess13022 a of the tubular barrel connector 13022 for fluidicly sealing theinterface between the tubular barrel connector and the sealingcartridge. Torsional locking pins, 13024 a and 13024 b, are coupled toand mounted within the external radial mounting holes, 13022 b and 13022c, respectively, of the barrel connector 13022 and received within theradial passages, 13018 d and 13018 e, of the tubular actuator barrel13018.

The other end of the tubular barrel connector 13022 is threadablycoupled to and is received within an end of a tubular actuator barrel13026 that defines a longitudinal passage 13026 a, radial passages,13026 b and 13026 c, and radial passages, 13026 d and 13026 e. Torsionallocking pins, 13028 a and 13028 b, are coupled to and mounted within theexternal radial mounting holes, 13022 f and 13022 g, respectively, ofthe tubular barrel connector 13022 and received within the radialpassages, 13026 b and 13026 c, of the tubular actuator barrel 13026. Theother end of the tubular actuator barrel 13026 receives and isthreadably coupled to an end of a tubular barrel connector 13030 thatdefines an internal annular recess 13030 a, external radial mountingholes, 13030 b and 13030 c, radial passages, 13030 d and 13030 e, andexternal radial mounting holes, 13030 f and 13030 g. A sealing cartridge13032 is received within and coupled to the internal annular recess13030 a of the tubular barrel connector 13030 for fluidicly sealing theinterface between the tubular barrel connector and the sealingcartridge. Torsional locking pins, 13034 a and 13034 b, are coupled toand mounted within the external radial mounting holes, 13030 b and 13030c, respectively, of the tubular barrel connector 13030 and receivedwithin the radial passages, 13026 d and 13026 e, of the tubular actuatorbarrel 13026.

The other end of the tubular barrel connector 13030 is threadablycoupled to and is received within an end of a tubular actuator barrel13036 that defines a longitudinal passage 13036 a, radial passages,13036 b and 13036 c, and radial passages, 13036 d and 13036 e. Torsionallocking pins, 13038 a and 13038 b, are coupled to and mounted within theexternal radial mounting holes, 13030 f and 13030 g, respectively, ofthe tubular barrel connector 13030 and received within the radialpassages, 13036 b and 13036 c, of the tubular actuator barrel 13036. Theother end of the tubular actuator barrel 13036 receives and isthreadably coupled to an end of a tubular barrel connector 13040 thatdefines an internal annular recess 13040 a, external radial mountingholes, 13040 b and 13040 c, radial passages, 13040 d and 13040 e, andexternal radial mounting holes, 13040 f and 13040 g. A sealing cartridge13042 is received within and coupled to the internal annular recess13040 a of the tubular barrel connector 13040 for fluidicly sealing theinterface between the tubular barrel connector and the sealingcartridge. Torsional locking pins, 13044 a and 13044 b, are coupled toand mounted within the external radial mounting holes, 13040 b and 13040c, respectively, of the tubular barrel connector 13040 and receivedwithin the radial passages, 13036 d and 13036 e, of the tubular actuatorbarrel 13036.

The other end of the tubular barrel connector 13040 is threadablycoupled to and is received within an end of a tubular actuator barrel13046 that defines a longitudinal passage 13046 a, radial passages,13046 b and 13046 c, and radial passages, 13046 d and 13046 e. Torsionallocking pins, 13048 a and 13048 b, are coupled to and mounted within theexternal radial mounting holes, 13040 f and 13040 g, respectively, ofthe tubular barrel connector 13040 and received within the radialpassages, 13046 b and 13046 c, of the tubular actuator barrel 13046. Theother end of the tubular actuator barrel 13046 receives and isthreadably coupled to an end of a tubular barrel connector 13050 thatdefines an internal annular recess 13050 a, external radial mountingholes, 13050 b and 13050 c, radial passages, 13050 d and 13050 e, andexternal radial mounting holes, 13050 f and 13050 g. A sealing cartridge13052 is received within and coupled to the internal annular recess13050 a of the tubular barrel connector 13050 for fluidicly sealing theinterface between the tubular barrel connector and the sealingcartridge. Torsional locking pins, 13054 a and 13054 b, are coupled toand mounted within the external radial mounting holes, 13050 b and 13050c, respectively, of the tubular barrel connector 13050 and receivedwithin the radial passages, 13046 d and 13046 e, of the tubular actuatorbarrel 13046.

The other end of the tubular barrel connector 13050 is threadablycoupled to and is received within an end of a tubular actuator barrel13056 that defines a longitudinal passage 13056 a, radial passages,13056 b and 13056 c, and radial passages, 13056 d and 13056 e. Torsionallocking pins, 13058 a and 13058 b, are coupled to and mounted within theexternal radial mounting holes, 13050 f and 13050 g, respectively, ofthe tubular barrel connector 13050 and received within the radialpassages, 13056 b and 13056 c, of the tubular actuator barrel 13056. Theother end of the tubular actuator barrel 13056 receives and isthreadably coupled to an end of a tubular lower stop 13060 that definesan internal annular recess 13060 a, external radial mounting holes,13060 b and 13060 c, and an internal annular recess 13060 d thatincludes one or more circumferentially spaced apart locking teeth 13060e at one end and one or more circumferentially spaced apart lockingteeth 13060 f at the other end. A sealing cartridge 13062 is receivedwithin and coupled to the internal annular recess 13060 a of the tubularlower stop 13060 for fluidicly sealing the interface between the tubularlower stop and the sealing cartridge. Torsional locking pins, 13064 aand 13064 b, are coupled to and mounted within the external radialmounting holes, 13060 b and 13060 c, respectively, of the tubular lowerstop 13060 and received within the radial passages, 13056 d and 13056 e,of the tubular actuator barrel 13056.

A connector tube 13066 that defines a longitudinal passage 13066 a andradial mounting holes, 13066 b and 13066 c, and includes externalsplines 13066 d at one end for engaging the internal splines 13014 b ofthe tubular member 13014 and radial mounting holes, 13066 e and 13066 f,at another end is received within and sealingly and movably engages theinterior surface of the sealing cartridge 13010 mounted within theannular recess 13008 a of the tubular barrel connector 13008. In thismanner, during longitudinal displacement of the connector tube 13066relative to the tubular barrel connector 13008, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the tubular barrel connector. An end of theconnector tube 13066 also receives and mates with the other end of thetubular guide member 13016. Mounting screws, 13068 a and 13068 b, arecoupled to and received within the radial mounting holes, 13066 b and13066 c, respectively of the connector tube 13066.

The other end of the connector tube 13066 is received within andthreadably coupled to an end of a tubular piston 13070 that defines alongitudinal passage 13070 a, radial mounting holes, 13070 b and 13070c, radial passages, 13070 d and 13070 e, and radial mounting holes,13070 f and 13070 g, that includes a flange 13070 h at one end. Asealing cartridge 13072 is mounted onto and sealingly coupled to theexterior of the tubular piston 13070 proximate the flange 13070 h. Thesealing cartridge 13072 also mates with and sealingly engages theinterior surface of the tubular actuator barrel 13018. In this manner,during longitudinal displacement of the tubular piston 13070 relative tothe actuator barrel 13018, a fluidic seal is maintained between theexterior surface of the piston and the interior surface of the actuatorbarrel. Mounting screws, 13074 a and 13074 b, are coupled to and mountedwithin the external radial mounting holes, 13070 b and 13070 c,respectively, of the tubular piston 13070 and received within the radialpassages, 13066 e and 13066 f, of the connector tube 13066.

The other end of the tubular piston 13070 receives and is threadablycoupled to an end of a connector tube 13076 that defines a longitudinalpassage 13076 a, radial mounting holes, 13076 b and 13076 c, at one endand radial mounting holes, 13076 d and 13076 e, at another end. Theconnector tube 13076 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 13024 mountedwithin the annular recess 13022 a of the tubular barrel connector 13022.In this manner, during longitudinal displacement of the connector tube13076 relative to the tubular barrel connector 13022, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the barrel connector. Mounting screws, 13078 a and13078 b, are coupled to and mounted within the external radial mountingholes, 13070 f and 13070 g, respectively, of the tubular piston 13070and received within the radial passages, 13076 b and 13076 c, of theconnector tube 13076.

The other end of the connector tube 13076 is received within andthreadably coupled to an end of a tubular piston 13080 that defines alongitudinal passage 13080 a, radial mounting holes, 13080 b and 13080c, radial passages, 13080 d and 13080 e, and radial mounting holes,13080 f and 13080 g, that includes a flange 13080 h at one end. Asealing cartridge 13082 is mounted onto and sealingly coupled to theexterior of the tubular piston 13080 proximate the flange 13080 h. Thesealing cartridge 13082 also mates with and sealingly engages theinterior surface of the tubular actuator barrel 13026. In this manner,during longitudinal displacement of the tubular piston 13080 relative tothe tubular actuator barrel 13026, a fluidic seal is maintained betweenthe exterior surface of the piston and the interior surface of theactuator barrel. Mounting screws, 13084 a and 13084 b, are coupled toand mounted within the external radial mounting holes, 13080 b and 13080c, respectively, of the tubular piston 13080 and received within theradial passages, 13076 e and 13076 f, of the connector tube 13076.

The other end of the tubular piston 13080 receives and is threadablycoupled to an end of a connector tube 13086 that defines a longitudinalpassage 13086 a, radial mounting holes, 13086 b and 13086 c, at one endand radial mounting holes, 13086 d and 13086 e, at another end. Theconnector tube 13086 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 13032 mountedwithin the annular recess 13030 a of the tubular barrel connector 13030.In this manner, during longitudinal displacement of the connector tube13086 relative to the tubular barrel connector 13030, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the barrel connector. Mounting screws, 13088 a and13088 b, are coupled to and mounted within the external radial mountingholes, 13080 f and 13080 g, respectively, of the tubular piston 13080and received within the radial passages, 13086 b and 13086 c, of theconnector tube 13086.

The other end of the connector tube 13086 is received within andthreadably coupled to an end of a tubular piston 13090 that defines alongitudinal passage 13090 a, radial mounting holes, 13090 b and 13090c, radial passages, 13090 d and 13090 e, and radial mounting holes,13090 f and 13090 g, that includes a flange 13090 h at one end. Asealing cartridge 13092 is mounted onto and sealingly coupled to theexterior of the tubular piston 13090 proximate the flange 13090 h. Thesealing cartridge 13092 also mates with and sealingly engages theinterior surface of the tubular actuator barrel 13036. In this manner,during longitudinal displacement of the tubular piston 13090 relative tothe tubular actuator barrel 13036, a fluidic seal is maintained betweenthe exterior surface of the piston and the interior surface of theactuator barrel. Mounting screws, 13094 a and 13094 b, are coupled toand mounted within the external radial mounting holes, 13090 b and 13090c, respectively, of the tubular piston 13090 and received within theradial passages, 13086 e and 13086 f, of the connector tube 13086.

The other end of the tubular piston 13090 receives and is threadablycoupled to an end of a connector tube 13096 that defines a longitudinalpassage 13096 a, radial mounting holes, 13096 b and 13096 c, at one endand radial mounting holes, 13096 d and 13096 e, at another end. Theconnector tube 13096 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 13042 mountedwithin the annular recess 13040 a of the tubular barrel connector 13040.In this manner, during longitudinal displacement of the connector tube13096 relative to the tubular barrel connector 13040, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the barrel connector. Mounting screws, 13098 a and13098 b, are coupled to and mounted within the external radial mountingholes, 13090 f and 13090 g, respectively, of the tubular piston 13090and received within the radial passages, 13096 b and 13096 c, of theconnector tube 13096.

The other end of the connector tube 13096 is received within andthreadably coupled to an end of a tubular piston 13100 that defines alongitudinal passage 13100 a, radial mounting holes, 13100 b and 13100c, radial passages, 13100 d and 13100 e, and radial mounting holes,13100 f and 13100 g, that includes a flange 13100 h at one end. Asealing cartridge 13102 is mounted onto and sealingly coupled to theexterior of the tubular piston 13100 proximate the flange 13100 h. Thesealing cartridge 13102 also mates with and sealingly engages theinterior surface of the tubular actuator barrel 13046. In this manner,during longitudinal displacement of the tubular piston 13100 relative tothe tubular actuator barrel 13046, a fluidic seal is maintained betweenthe exterior surface of the piston and the interior surface of theactuator barrel. Mounting screws, 13104 a and 13104 b, are coupled toand mounted within the external radial mounting holes, 13100 b and 13100c, respectively, of the tubular piston 13100 and received within theradial passages, 13096 e and 13096 f, of the connector tube 13096.

The other end of the tubular piston 13100 receives and is threadablycoupled to an end of a connector tube 13106 that defines a longitudinalpassage 13106 a, radial mounting holes, 13106 b and 13106 c, at one endand radial mounting holes, 13106 d and 13106 e, at another end. Theconnector tube 13106 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 13052 mountedwithin the annular recess 13050 a of the tubular barrel connector 13050.In this manner, during longitudinal displacement of the connector tube13106 relative to the tubular barrel connector 13050, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the barrel connector. Mounting screws, 13108 a and13108 b, are coupled to and mounted within the external radial mountingholes, 13100 f and 13100 g, respectively, of the tubular piston 13100and received within the radial passages, 13106 b and 13106 c, of theconnector tube 13106.

The other end of the connector tube 13106 is received within andthreadably coupled to an end of a tubular piston 13110 that defines alongitudinal passage 13110 a, radial mounting holes, 13110 b and 13110c, radial passages, 13110 d and 13110 e, radial mounting holes, 13110 fand 13110 g, that includes a flange 13110 h at one end andcircumferentially spaced teeth 13110 i at another end for engaging theone or more circumferentially spaced apart locking teeth 13060 e of thetubular lower stop 13060. A sealing cartridge 13112 is mounted onto andsealingly coupled to the exterior of the tubular piston 13110 proximatethe flange 13110 h. The sealing cartridge 13112 also mates with andsealingly engages the interior surface of the actuator barrel 13056. Inthis manner, during longitudinal displacement of the tubular piston13110 relative to the actuator barrel 13056, a fluidic seal ismaintained between the exterior surface of the piston and the interiorsurface of the actuator barrel. Mounting screws, 13114 a and 13114 b,are coupled to and mounted within the external radial mounting holes,13110 b and 13110 c, respectively, of the tubular piston 13110 andreceived within the radial passages, 13106 d and 13106 e, of theconnector tube 13106.

The other end of the tubular piston 13110 receives and is threadablycoupled to an end of a connector tube 13116 that defines a longitudinalpassage 13116 a, radial mounting holes, 13116 b and 13116 c, at one endand radial mounting holes, 13116 d and 13116 e, at another end thatincludes an external flange 13116 f that includes circumferentiallyspaced apart teeth 13116 g that extend from an end face of the externalflange for engaging the teeth 13060 f of the tubular lower stop 13060,and an externally threaded connection 13116 h at another end. Theconnector tube 13116 is received within and sealingly and movablyengages the interior surface of the sealing cartridge 13062 mountedwithin the annular recess 13060 a of the lower tubular stop 13060. Inthis manner, during longitudinal displacement of the connector tube13116 relative to the lower tubular stop 13060, a fluidic seal ismaintained between the exterior surface of the connector tube and theinterior surface of the lower tubular stop. Mounting screws, 13118 a and13118 b, are coupled to and mounted within the external radial mountingholes, 13110 f and 13110 g, respectively, of the tubular piston 13110and received within the radial passages, 13116 b and 13116 c, of theconnector tube 13116.

In an exemplary embodiment, as illustrated in FIGS. 13A1 to 13A8, theinternally threaded connection 13002 e of the upper tubular supportmember 13002 receives and is coupled to the externally threadedconnection 1234 g of the lower mandrel 1234 of the ball grabber assembly16 and the externally threaded connection 13116 h of the connector tube13116 is received within and is coupled to an internally threadedconnection 20 a of an end of the safety sub assembly 20.

In an exemplary embodiment, as illustrated in FIGS. 13A1 to 13A8, duringoperation of the tension actuator assembly 18, the tension actuatorassembly is positioned within the expandable wellbore casing 100 andfluidic material 13200 is injected into the tension actuator assemblythrough the passages 13002 a, 13016 a, 13066 a, 13070 a, 13076 a, 13080a, 13086 a, 13090 a, 13096 a, 13100 a, 13106 a, 13110 a, and 13116 a.The injected fluidic material 13200 will also pass through the radialpassages, 13070 d and 13070 e, 13080 d and 13080 e, 13090 d and 13090 e,13100 d and 13100 e, 13110 d and 13110 e, of the tubular pistons, 13070,13080, 13090, 13100, and 13110, respectively, into annular pistonchambers, 13202, 13204, 13206, 13208, 13208, and 13210.

As illustrated in FIGS. 13B1 to 13B7, the operating pressure of thefluidic material 13200 may then be increased by, for example,controllably blocking or limiting the flow of the fluidic materialthrough the passage 13116 a and/or increasing the operating pressure ofthe outlet of a pumping device for injecting the fluidic material 13200into the tension actuator assembly 18. As a result, of the increasedoperating pressure of the fluidic material 13200 within the tensionactuator assembly 18, the operating pressures of the annular pistonchambers, 13202, 13204, 13206, 13208, 13208, and 13210, will beincreased sufficiently to displace the tubular pistons, 13070, 13080,13090, 13100, and 13110, upwardly in the direction 13212 thereby alsodisplacing the connector tube 13116. As a result, a upward tensile forceis applied to all elements of the system 10 coupled to and positionedbelow the connector tube 13116. In an exemplary embodiment, during theupward displacement of the tubular pistons, 13070, 13080, 13090, 13100,and 13110, fluidic materials displaced by the tubular pistons withindischarge annular chambers, 13214, 13216, 13218, 13220, and 13222 areexhausted out of the tension actuator assembly 18 through the radialpassages, 13008 d and 13008 e, 13022 d and 13022 e, 13030 d and 13030 e,13040 d and 13040 e, 13050 d and 13050 e, respectively. Furthermore, inan exemplary embodiment, the upward displacement of the tubular pistons,13070, 13080, 13090, 13100, and 13110, further causes the externalsplines 13066 d of the connector tube 13066 to engage the internalsplines 13014 b of the tubular member 13014 and the circumferentiallyspaced apart teeth 13116 g of the connector tube 13116 to engage thecircumferentially spaced teeth 13060 f of the tubular lower stop 13060.As a result of the interaction of the external splines 13066 d of theconnector tube 13066 to engage the internal splines 13014 b of thetubular member 13014 and the circumferentially spaced apart teeth 13116g of the connector tube 13116 to engage the circumferentially spacedteeth 13060 f of the tubular lower stop 13060, torsional loads may betransmitted through the tension actuator assembly 18.

In an exemplary embodiment, the sealing cup assembly 22 operates and isprovided substantially, at least in part, as disclosed in one or more ofthe following: (1) PCT patent application Ser. No. PCT/US02/36157, filedon Nov. 12, 2002, (2) PCT patent application Ser. No. PCT/US02/36267,filed on Nov. 12, 2002, (3) PCT patent application Ser. No.PCT/US03/04837, filed on Feb. 29, 2003, (4) PCT patent application Ser.No. PCT/US03/29859, filed on Sep. 22, 2003, (5) PCT patent applicationSer. No. PCT/US03/14153, filed on Nov. 13, 2003, and/or (6) PCT patentapplication Ser. No. PCT/US03/18530, filed on Jun. 11, 2003, thedisclosures of which are incorporated herein by reference.

In an exemplary embodiment, the casing lock assembly 24 operates and isprovided substantially, at least in part, as disclosed in one or more ofthe following: (1) PCT patent application Ser. No. PCT/US02/36267, filedon Nov. 12, 2002, (2) PCT patent application Ser. No. PCT/US03/29859,filed on Sep. 22, 2003, and/or (3) PCT patent application serial numberPCT/US03/14153, filed on Nov. 13, 2003, the disclosures of which areincorporated herein by reference.

In an exemplary embodiment, the adjustable bell section expansion coneassembly 28 operates and is provided substantially, at least in part, asdisclosed in one or more of the following: (1) PCT patent applicationSer. No. PCT/US02/36157, filed on Nov. 12, 2002, (2) PCT patentapplication Ser. No. PCT/US02/36267, filed on Nov. 12, 2002, (3) PCTpatent application Ser. No. PCT/US03/04837, filed on Feb. 29, 2003, (4)PCT patent application Ser. No. PCT/US03/29859,. filed on Sep. 22, 2003,(5) PCT patent application Ser. No. PCT/US03/14153, filed on Nov. 13,2003, and/or (6) PCT patent application Ser. No. PCT/US03/18530, filedon Jun. 11, 2003, the disclosures of which are incorporated herein byreference.

In an alternative embodiment, the adjustable bell section expansion coneassembly 28 further incorporates one or more of the elements and/orteachings of the casing cutter assembly 14 for sensing the internaldiameter of the expandable wellbore casing 100.

In an exemplary embodiment, the adjustable casing expansion coneassembly 30 operates and is provided substantially, at least in part, asdisclosed in one or more of the following: (1) PCT patent applicationSer. No. PCT/US02/36157, filed on Nov. 12, 2002, (2) PCT patentapplication Ser. No. PCT/US02/36267, filed on Nov. 12, 2002, (3) PCTpatent application Ser. No. PCT/US03/04837, filed on 2129/03, (4) PCTpatent application Ser. No. PCT/US03/29859, filed on Sep. 22, 2003, (5)PCT patent application Ser. No. PCT/US03/14153, filed on Nov. 13, 2003,and/or (6) PCT patent application Ser. No. PCT/US03/18530, filed on Jun.11, 2003, the disclosures of which are incorporated herein by reference.

In an alternative embodiment, the adjustable casing expansion coneassembly 30 further incorporates one or more of the elements and/orteachings of the casing cutter assembly 14 for sensing the internaldiameter of the expandable wellbore casing 100.

In an exemplary embodiment, as illustrated in 14A to 14C, the packersetting tool assembly 32 includes a tubular adaptor 1402 that defines alongitudinal passage 1402 a, radial external mounting holes, 1402 b and1402 c, radial passages, 1402 d and 1402 e, and includes an externalthreaded connection 1402 f at one end and an internal annular recess1402 g having an internal threaded connection at another end. Anexternal threaded connection 1404 a of an end of a tubular upper mandrel1404 that defines a longitudinal passage 1404 b, internally threadedexternal mounting holes, 1404 c and 1404 d, and includes an externalannular recess 1404 e, external annular recess 1404 f, external annularrecess 1404 g, external flange 1404 h, external splines 1404 i, and aninternal threaded connection 1404 j at another end is received withinand is coupled to the internally threaded connection of the internalannular recess 1402 g of the other end of the tubular adaptor 1402.Mounting screws, 1405 a and 1405 b, are received within and coupled tothe mounting holes, 1404 c and 1404 d, of the tubular upper mandrel 1404that also extend into the radial passages, 1402 d and 1402 e, of thetubular adaptor 1402.

An external threaded connection 1406 a of an end of a mandrel 1406 thatdefines a longitudinal passage 1406 b and includes an external annularrecess 1406 c and an external annular recess 1406 d having an externalthreaded connection is received within and is coupled to the internalthreaded connection 1404 j of the tubular upper mandrel 1404. Aninternal threaded connection 1408 a of a tubular stinger 1408 thatdefines a longitudinal passage 1408 b and includes an external annularrecess 1408 c, and an external tapered annular recess 1408 d and anengagement shoulder 1408 e at another end receives and is coupled to theexternal threaded connection of the external annular recess 1406 d ofthe mandrel 1406. A sealing member 1410 is mounted upon and coupled tothe external annular recess 1406 d of the mandrel 1406.

An internal flange 1412 a of a tubular key 1412 that includes anexternal annular recess 1412 b at one end and an internal annular recess1412 c at another end is movably received within and engages theexternal annular recess 1404 f of the tubular upper mandrel 1404. Agarter spring 1414 is received within and engages the external annularrecess 1412 b of the tubular key 1412.

An end of a tubular bushing 1416 that defines a longitudinal passage1416 a for receiving and mating with the upper mandrel 1404, and radialpassages, 1416 b and 1416 c, and includes an external threadedconnection 1416 d at an intermediate portion, and an external flange1416 e, an internal annular recess 1416 f, circumferentially spacedapart teeth 1416 g, and external flanges, 1416 h and 1416 i, at anotherend is received within and mates with the internal annular recess 1412 cof the tubular key 1412. An internal threaded connection 1418 a of atubular drag block body 1418 that defines a longitudinal passage 1418 bfor receiving the tubular bushing 1416, mounting holes, 1418 c and 1418d, mounting holes, 1418 e and 1418 f, and includes an internal threadedconnection 1418 g at one end, a centrally positioned external annularrecess 1418 h, and an external threaded connection 1418 i at another endis received within and coupled to the external threaded connection 1416d of the tubular bushing 1416.

A first tubular keeper 1420 that defines mounting holes, 1420 a and 1420b, is coupled to an end of the tubular drag block body 1418 by mountingscrews, 1422 a and 1422 b, that are received within and are coupled tothe mounting holes, 1418 c and 1418 d, of the tubular drag block body. Asecond tubular keeper 1424 that defines mounting holes, 1424 a and 1424b, is coupled to an end of the tubular drag block body 1418 by mountingscrews, 1426 a and 1426 b, that are received within and are coupled tothe mounting holes, 1418 e and 1418 f, of the tubular drag block body.

Drag blocks, 1428 and 1430, that are received within the externalannular recess 1418 h of the tubular drag block body 1418, include endsthat mate with and are received within the end of the first tubularkeeper 1420, and other ends that mate with and are received within theend of the second tubular keeper 1424. The drag blocks, 1428 and 1430,further include internal annular recesses, 1428 a and 1430 a,respectively, that receive and mate with ends of springs, 1432 and 1434,respectively. The springs, 1432 and 1434, also receive and mate with theexternal annular recess 1418 h of the tubular drag block body 1418.

An external threaded connection 1436 a of an end of a tubular releasingcap extension 1436 that defines a longitudinal passage 1436 b andincludes an internal annular recess 1436 c and an internal threadedconnection 1436 d at another end is received within and is coupled tothe internal threaded connection 1418 g of the tubular drag block body1418. An external threaded connection 1438 a of an end of a tubularreleasing cap 1438 that defines a longitudinal passage 1438 b andincludes an internal annular recess 1438 c is received within andcoupled to the internal threaded connection 1436 d of the tubularreleasing cap extension 1436. A sealing element 1440 is received withinthe internal annular recess 1438 c of the tubular releasing cap 1438 forfluidicly sealing the interface between the tubular releasing cap andthe upper mandrel 1404.

An internal threaded connection 1442 a of an end of a tubular settingsleeve 1442 that defines a longitudinal passage 1442 b, radial passage1442 c, radial passages, 1442 d and 1442 e, radial passage 1442 f, andincludes an internal flange 1442 g at another end receives the externalthreaded connection 1418 i of the tubular drag block body 1418. Aninternal flange 1444 a of a tubular coupling ring 1444 that defines alongitudinal passage 1444 b and radial passages, 1444 c and 1444 d,receives and mates with the external flange 1416 h of the tubularbushing 1416 and an end face of the internal flange of the tubularcoupling ring is positioned proximate and in opposing relation to an endface of the external flange 1416 i of the tubular bushing.

An internal flange 1446 a of a tubular retaining collet 1446 thatincludes a plurality of axially extending collet fingers 1446 b, eachhaving internal flanges 1446 c at an end of each collet finger, forengaging and receiving the tubular coupling ring 1444 receives and mateswith external flange 1416 e of the tubular bushing 1416 and an end faceof the internal flange of the tubular retaining collet is positionedproximate and in opposing relation to an end face of the external flange1416 h of the tubular bushing.

In an exemplary embodiment, the packer assembly 36 operates and isprovided substantially, at least in part, as disclosed in one or more ofthe following: (1) PCT patent application Ser. No. PCT/US03/14153, filedon Nov. 13, 2003, and/or (2) PCT patent application Ser. No.PCT/US03/29460, filed on Sep. 23, 2003, the disclosures of which areincorporated herein by reference.

In an exemplary embodiment, as illustrated in FIGS. 15-1 to 15-5, thepacker assembly 36 includes a tubular upper adaptor 1502 that defines alongitudinal passage 1502 a having a tapered opening 1502 b and mountingholes, 1502 c and 1502 d, that includes a plurality of circumferentiallyspaced apart teeth 1502 e at one end, an external flange 1502 f, and aninternal threaded connection 1502 g at another end. In an exemplaryembodiment, the tubular upper adaptor 1502 is fabricated from aluminum.An external threaded connection 1504 a of an end of a tubular uppermandrel 1504 that defines a longitudinal passage 1504 b, mounting holes,1504 c and 1504 d, mounting holes, 1504 e and 1504 f, and mountingholes, 1504 g and 1504 h, and includes an external flange 1504 i, aninternal annular recess 1504 j, and an internal threaded connection 1504k at another end is received within and coupled to the internal threadedconnection 1502 g of the tubular upper adaptor 1502. In an exemplaryembodiment, the tubular upper mandrel 1504 is fabricated from aluminum.

An upper tubular spacer ring 1506 that defines mounting holes, 1506 aand 1506 b, receives and mates with the end of the tubular upper mandrel1504 and includes an angled end face 1506 c and another end face that ispositioned proximate to an end face of the tubular upper adaptor 1502 iscoupled to the tubular upper mandrel by shear pins, 1508 a and 1508 b,that are mounted within and coupled to the mounting holes, 1504 c and1506 a, and, 1504 d and 1506 b, respectively, of the tubular uppermandrel and upper tubular spacer ring, respectively. A lower tubularspacer ring 1510 that includes an angled end face 1510 a receives,mates, and is coupled to the other end of the tubular upper mandrel 1504and includes another end face that is positioned proximate to an endface of the external flange 1504 i of the tubular upper mandrel 1504. Inan exemplary embodiment, the upper and tubular spacer rings, 1506 and1510, are fabricated from a composite material.

An upper tubular slip 1512 that receives and is movably mounted upon thetubular upper mandrel 1504 defines a longitudinal passage 1512 a havinga tapered opening 1512 b and includes external annular recesses, 1512 c,1512 d, 1512 e, 1512 f, and 1512 g, and an angled end face 1512 h thatmates with and is positioned proximate the angled end face 1506 c of theupper tubular spacer ring 1506. Slip retaining bands, 1514 a, 1514 b,1514 c, 1514 d, and 1514 e, are received within and coupled to theexternal annular recesses, 1512 c, 1512 d, 1512 e, 1512 f, and 1512 g,of the upper tubular slip 1512. A lower tubular slip 1516 that receivesand is movably mounted upon the tubular upper mandrel 1504 defines alongitudinal passage 1516 a having a tapered opening 1516 b and includesexternal annular recesses, 1516 c, 1516 d, 1516 e, 1516 f, and 1516 g,and an angled end face 1516 h that mates with and is positionedproximate the angled end face 1510 a of the lower tubular spacer ring1510. Slip retaining bands, 1518 a, 1518 b, 1518 c, 1518 d, and 1518 e,are received within and coupled to the external annular recesses, 1516c, 1516 d, 1516 e, 1516 f, and 1516 g, of the lower tubular slip 1516.In an exemplary embodiment, the upper and lower tubular slips, 1512 and1516, are fabricated from composite materials, and at least some of theslip retaining bands, 1514 a, 1514 b, 1514 c, 1514 d, 1514 e, 1518 a,1518 b, 1518 c, 1518 d, and 1518 e are fabricated from carbide insertmaterials.

An upper tubular wedge 1520 that defines an longitudinal passage 1520 afor receiving the tubular upper mandrel 1504 and mounting holes, 1520 band 1520 c, and includes an angled end face 1520 d at one end that isreceived within and mates with the tapered opening 1512 b of the uppertubular slip 1512, and an angled end face 1520 e at another end iscoupled to the tubular upper mandrel by shear pins, 1522 a and 1522 b,mounted within and coupled to the mounting holes, 1504 e and 1520 b,and, 1504 f and 1520 c, respectively, of the tubular upper mandrel andupper tubular wedge, respectively. A lower tubular wedge 1524 thatdefines an longitudinal passage 1524 a for receiving the tubular uppermandrel 1504 and mounting holes, 1524 b and 1524 c, and includes anangled end face 1524 d at one end that is received within and mates withthe tapered opening 1516 b of the lower tubular slip 1516, and an angledend face 1524 e at another end is coupled to the tubular upper mandrelby shear pins, 1526 a and 1526 b, mounted within and coupled to themounting holes, 1504 g and 1524 b, and, 1504 h and 1524 c, respectively,of the tubular upper mandrel and lower tubular wedge, respectively. Inan exemplary embodiment, the upper and lower tubular wedges, 1520 and1524, are fabricated from composite materials.

An upper tubular extrusion limiter 1528 that defines a longitudinalpassage 1528 a for receiving the tubular upper mandrel 1504 includes anangled end face 1528 b at one end that mates with the angled end face1520 e of the upper tubular wedge 1520, an angled end face 1528 c atanother end having recesses 1528 d, and external annular recesses, 1528e, 1528 f and 1528 g. Retaining bands, 1530 a, 1530 b, and 1530 c, aremounted within and coupled to the external annular recesses, 1528 e,1528 f and 1528 g, respectively, of the upper tubular extrusion limiter1528. Circular disc-shaped extrusion preventers 1532 are coupled andmounted within the recesses 1528 d. A lower tubular extrusion limiter1534 that defines a longitudinal passage 1534 a for receiving thetubular upper mandrel 1504 includes an angled end face 1534 b at one endthat mates with the angled end face 1524 e of the lower tubular wedge1524, an angled end face 1534 c at another end having recesses 1534 d,and external annular recesses, 1534 e, 1534 f and 1534 g. Retainingbands, 1536 a, 1536 b, and 1536 c, are mounted within and coupled to theexternal annular recesses, 1534 e, 1534 f and 1534 g, respectively, ofthe lower tubular extrusion limiter 1534. Circular disc-shaped extrusionpreventers 1538 are coupled and mounted within the recesses 1534 d. Inan exemplary embodiment, the upper and lower extrusion limiters, 1528and 1534, are fabricated from composite materials.

An upper tubular elastomeric packer element 1540 that defines alongitudinal passage 1540 a for receiving the tubular upper mandrel 1504includes an angled end face 1540 b at one end that mates with and ispositioned proximate the angled end face 1528 c of the upper tubularextrusion limiter 1528 and an curved end face 1540 c at another end. Alower tubular elastomeric packer element 1542 that defines alongitudinal passage 1542 a for receiving the tubular upper mandrel 1504includes an angled end face 1542 b at one end that mates with and ispositioned proximate the angled end face 1534 c of the lower tubularextrusion limiter 1534 and an curved end face 1542 c at another end.

A central tubular elastomeric packer element 1544 that defines alongitudinal passage 1544 a for receiving the tubular upper mandrel 1504includes a curved outer surface 1544 b for mating with and engaging thecurved end faces, 1540 c and 1542 c, of the upper and lower tubularelastomeric packer elements, 1540 and 1542, respectively.

An external threaded connection 1546 a of a tubular lower mandrel 1546that defines a longitudinal passage 1546 b having throat passages, 1546c and 1546 d, and flow ports, 1546 e and 1546 f, and a mounting hole1546 g, and includes an internal annular recess 1546 h at one end, andan external flange 1546 i, internal annular recess 1546 j, and internalthreaded connection 1546 k at another end. In an exemplary embodiment,the tubular lower mandrel 1546 is fabricated from aluminum. A sealingelement 1548 is received within the inner annular recess 1504 j of theother end of the tubular upper mandrel 1504 for sealing an interfacesbetween the tubular upper mandrel and the tubular lower mandrel 1546.

A tubular sliding sleeve valve 1550 that defines a longitudinal passage1550 a and radial flow ports, 1550 b and 1550 c, and includes colletfingers 1550 d at one end for engaging the internal annular recess 1546h of the lower tubular mandrel 1546, an external annular recess 1550 e,an external annular recess 1550 f, an external annular recess 1550 g,and circumferentially spaced apart teeth 1550 h at another end isreceived within and is slidably coupled to the longitudinal passage 1546b of the tubular lower mandrel 1546. In an exemplary embodiment, thetubular sliding sleeve valve 1550 is fabricated from aluminum. A setscrew 1552 is mounted within and coupled to the mounting hole 1546 g ofthe tubular lower mandrel 1546 that is received within the externalannular recess 1550 e of the tubular sliding sleeve 1550. Sealingelements, 1554 and 1556, are mounted within the external annularrecesses, 1550 f and 1550 g, respectively, of the tubular sliding sleevevalve 1550 for sealing an interface between the tubular sliding sleevevalve and the tubular lower mandrel 1546.

An end of a tubular outer sleeve 1558 that defines a longitudinalpassage 1558 a, radial passages, 1558 b and 1558 c, upper flow ports,1558 d and 1558 e, lower flow ports, 1558 f and 1558 g, and radialpassages, 1558 h and 1558 i, receives, mates with, and is coupled to theother end of the tubular upper mandrel 1504 and an end face of the endof the tubular outer sleeve is positioned proximate and end face of thelower tubular spacer ring 1510. The other end of the tubular outersleeve 1558 receives, mates with, and is coupled to the other end of thetubular lower mandrel 1546.

An external threaded connection 1560 a of an end of a tubular bypassmandrel 1560 that defines a longitudinal passage 1560 b, upper flowports, 1560 c and 1560 d, lower flow ports, 1560 e and 1560 f, and amounting hole 1560 g and includes an internal annular recess 1560 h andan external threaded connection 1560 i at another end is received withinand coupled to the internal threaded connection 1546 k of the tubularlower mandrel 1546. A sealing element 1562 is received within theinternal annular recess 1546 j of the tubular lower mandrel 1546 forsealing an interface between the tubular lower mandrel and the tubularbypass mandrel 1560.

A tubular plug seat 1564 that defines a longitudinal passage 1564 ahaving a tapered opening 1564 b at one end, and flow ports, 1564 c and1564 d, and includes an external annular recess 1564 e, an externalannular recess 1564 f, an external annular recess 1564 g, an externalannular recess 1564 h, and an external annular recess 1564 i having anexternal threaded connection at another end is received within and ismovably coupled to the longitudinal passage 1560 b of the tubular bypassmandrel 1560. A tubular nose 1566 is threadably coupled to and mountedupon the external annular recess 1564 i of the tubular plug seat 1564.In an exemplary embodiment, the tubular plug seat 1564 is fabricatedfrom aluminum. Sealing elements, 1568, 1570, and 1572, are receivedwithin the external annular recesses, 1564 e, 1564 g, and 1564 h,respectively, of the tubular plug seat 1564 for sealing an interfacebetween the tubular plug seat and the tubular bypass mandrel 1560. A setscrew 1574 is mounted within and coupled to the mounting hole 1560 g ofthe tubular bypass mandrel 1560 that is received within the externalannular recess 1564 f of the tubular plug seat 1564.

An end of a tubular bypass sleeve 1576 that defines a longitudinalpassage 1576 a and includes an internal annular recess 1576 b at one endand an internal threaded connection 1576 c at another end is coupled tothe other end of the tubular outer sleeve 1558 and mates with andreceives the tubular bypass mandrel 1560. In an exemplary embodiment,the tubular bypass sleeve 1576 is fabricated from aluminum.

An external threaded connection 1578 a of a tubular valve seat 1578 thatdefines a longitudinal passage 1578 b including a valve seat 1578 c andup-jet flow ports, 1578 d and 1578 e, and includes a spring retainer1578 f and an external annular recess 1578 g is received within and iscoupled to the internal threaded connection 1576 c of the tubular bypasssleeve 1576. In an exemplary embodiment, the tubular valve seat 1578 isfabricated from aluminum. A sealing element 1580 is received within theexternal annular recess 1578 g of the tubular valve seat 1578 forfluidicly sealing an interface between the tubular valve seat and thetubular bypass sleeve 1576.

A poppet valve 1582 mates with and is positioned within the valve seat1578 c of the tubular valve seat 1578. An end of the poppet valve 1582is coupled to an end of a stem bolt 1584 that is slidingly supported forlongitudinal displacement by the spring retainer 1578 f A valve spring1586 that surrounds a portion of the stem bolt 1584 is positioned inopposing relation to the head of the stem bolt and a support 1578 fa ofthe spring retainer 1578 f. for biasing the poppet valve 1582 intoengagement with the valve seat 1578 c of the tubular valve seat 1578.

An end of a composite nose 1588 that defines a longitudinal passage 1588a and mounting holes, 1588 b and 1588 c, and includes an internalthreaded connection 1588 d at another end receives, mates with, and iscoupled to the other end of the tubular valve seat 1578. A tubular nosesleeve 1590 that defines mounting holes, 1590 a and 1590 b, is coupledto the composite nose 1588 by shear pins, 1592 a and 1592 b, that aremounted in and coupled to the mounting holes, 1588 b and 1590 a, and,1588 c and 1590 b, respectively, of the composite nose and tubular nosesleeve, respectively.

An external threaded connection 1594 a of a baffle nose 1594 thatdefines longitudinal passages, 1594 b and 1594 c, is received within andis coupled to the internal threaded connection internal threadedconnection 1588 d of the composite nose 1588.

In an exemplary embodiment, as illustrated in FIGS. 16A1 to 16A5, duringthe operation of the packer setting tool assembly 32 and packer assembly36, the packer setting tool and packer assembly are coupled to oneanother by inserting the end of the tubular upper adaptor 1502 into theother end of the tubular coupling ring 1444, bringing thecircumferentially spaced teeth 1416 g of the other end of the tubularbushing 1416 into engagement with the circumferentially spaced teeth1502 e of the end of the tubular upper adaptor, and mounting shear pins,1602 a and 1602 b, within the mounting holes, 1444 c and 1502 c, and,1444 d and 1502 d, respectively, of the tubular coupling ring andtubular upper adaptor, respectively. As a result, the tubular mandrel1406 and tubular stinger 1408 of the packer setting tool assembly 32 arethereby positioned within the longitudinal passage 1504 a of the tubularupper mandrel 1504 with the 1408 e of the tubular stinger positionedwithin the longitudinal passage 1546 b of the tubular lower mandrel 1546proximate the collet fingers 1550 d of the tubular sliding sleeve valve1550.

Furthermore, in an exemplary embodiment, during the operation of thepacker setting tool 32 and packer assembly 36, as illustrated in FIGS.16A1 to 16A5, the packer setting tool and packer assembly are positionedwithin the expandable wellbore casing 100 and an internal threadedconnection 30 a of an end of the adjustable casing expansion coneassembly 30 receives and is coupled to the external threaded connection1402 f of the end of the tubular adaptor 1402 of the packer setting toolassembly. Furthermore, shear pins, 1604 a and 1604 b, mounted within themounting holes, 1558 b and 1558 c, of the tubular outer sleeve 1558couple the tubular outer sleeve to the expandable wellbore casing. As aresult, torsion loads may transferred between the tubular outer sleeve1558 and the expandable wellbore casing 100.

In an exemplary embodiment, as illustrated in FIGS. 16B1 to 16B5, aconventional plug 1606 is then injected into the setting tool assembly32 and packer assembly 36 by injecting a fluidic material 1608 into thesetting tool assembly and packer assembly through the longitudinalpassages, 1402 a, 1404 b, 1406 b, 1408 b, 1550 a, 1546 a, 1560 b, and1564 a of the tubular adaptor 1402, tubular upper mandrel 1404, tubularmandrel 1406, tubular stinger 1408, tubular sliding sleeve valve 1550,tubular lower mandrel 1546, tubular bypass mandrel 1560, and tubularplug seat 1564, respectively. The plug 1606 is thereby positioned withinthe longitudinal passage 1564 a of the tubular plug seat 1564. Continuedinjection of the fluidic material 1608 following the seating of the plug1606 within the longitudinal passage 1564 a of the tubular plug seat1564 causes the plug and the tubular plug seat to be displaceddownwardly in a direction 1610 until further movement of the tubularplug seat is prevented by interaction of the set screw 1574 with theexternal annular recess 1564 f of the tubular plug seat. As a result,the flow ports, 1564 c and 1564 d, of the tubular plug seat 1564 aremoved out of alignment with the upper flow ports, 1560 c and 1560 d, ofthe tubular bypass mandrel 1560.

In an exemplary embodiment, as illustrated in FIGS. 16C1 to 16C5, afterthe expandable wellbore casing 100 has been radially expanded andplastically deformed to form at least the bell section 112 of theexpandable wellbore casing 100 thereby shearing the shear pins, 1604 aand 1604 b, the setting tool assembly 32 and packer assembly 36 are thenmoved upwardly to a position within the expandable wellbore casing 100above the bell section. The tubular adaptor 1402 is then rotated, byrotating the tool string of the system 10 above the setting toolassembly 32, to displace and position the drag blocks, 1428 and 1430,into engagement with the interior surface of the expandable wellborecasing 100.

As a result of the engagement of the drag blocks, 1428 and 1430, withthe interior surface of the expandable wellbore casing 100, furtherrotation of the drag blocks relative to the wellbore casing isprevented. Consequently, due to the operation and interaction of thethreaded connections, 1416 d and 1418 a, of the tubular bushing 1416 andtubular drag block body 1418, respectively, further rotation of thetubular adaptor 1402 causes the tubular drag block body and settingsleeve 1442 to be displaced downwardly in a direction 1612 relative tothe remaining elements of the setting tool assembly 32 and packerassembly 36. As a result, the setting sleeve 1442 engages and displacesthe upper tubular spacer ring 1506 thereby shearing the shear pins, 1522a and 1522 b, and driving the upper tubular slip 1512 onto and up theangled end face 1520 d of the upper tubular wedge 1520 and intoengagement with the interior surface of the expandable wellbore casing100. As a result, longitudinal displacement of the upper tubular slip1512 relative to the expandable wellbore casing 100 is prevented.Furthermore, as a result, the 1446 b collet fingers of the tubularretaining collet 1446 are disengaged from the tubular upper adaptor1502.

In an alternative embodiment, after the drag blocks, 1428 and 1430,engage the interior surface of the expandable wellbore casing 100, anupward tensile force is applied to the tubular support member 12, andthe ball gripper assembly 16 is then operate to engage the interiorsurface of the expandable wellbore casing. The tension actuator assembly18 is then operated to apply an upward tensile force to the tubularadaptor 1402 thereby pulling the upper tubular spacer ring 1506, lowertubular spacer ring 1510, upper tubular slip 1512, lower tubular slip1516, upper tubular wedge 1520, lower tubular wedge 1524, upper tubularextrusion limiter 1528, lower tubular extrusion limiter 1534, andcentral tubular elastomeric element 1544 upwardly into contact with the1442 thereby compressing the upper tubular spacer ring, lower tubularspacer ring, upper tubular slip, lower tubular slip, upper tubularwedge, lower tubular wedge, upper tubular extrusion limiter, lowertubular extrusion limiter, and central tubular elastomeric element. As aresult, the upper tubular slip 1512, lower tubular slip 1516, andcentral tubular elastomeric element 1544 engage the interior surface ofthe expandable wellbore casing 100.

In an exemplary embodiment, as illustrated in FIGS. 16D1 to 16D5, anupward tensile force is then applied to the tubular adaptor 1402 therebycompressing the lower tubular slip 1516, lower tubular wedge 1524,central elastomeric packer element 1544, upper tubular extrusion limiter1528, and upper tubular wedge 1520 between the lower tubular spacer ring1510 and the stationary upper tubular slip 1512. As a result, the lowertubular slip 1516 is driven onto and up the angled end face 1524 d ofthe lower tubular wedge 1524 and into engagement with the interiorsurface of the expandable wellbore casing 100, and the centralelastomeric packer element 1544 is compressed radially outwardly intoengagement with the interior surface of the expandable tubular member.As a result, further longitudinal displacement of the upper tubular slip1512, lower tubular slip 1516, and central elastomeric packer element1544 relative to the expandable wellbore casing 100 is prevented.

In an exemplary embodiment, as illustrated in FIGS. 16E1 to 16E6,continued application of the upward tensile force to tubular adaptor1402 will then shear the shear pins, 1602 a and 1602 b, therebydisengaging the setting tool assembly 32 from the packer assembly 36.

In an exemplary embodiment, as illustrated in FIGS. 16F1 to 16F6, withthe drag blocks, 1428 and 1430, in engagement with the interior surfaceof the expandable wellbore casing 100, the tubular adaptor 102 isfurther rotated thereby causing the tubular drag block body 1418 andsetting sleeve 1442 to be displaced further downwardly in the direction1612 until the tubular drag block body and setting sleeve are disengagedfrom the tubular stinger 1408. As a result, the tubular stinger 1408 ofthe setting tool assembly 32 may then be displaced downwardly intocomplete engagement with the tubular sliding sleeve valve 1550.

In an exemplary embodiment, as illustrated in FIGS. 16G1 to 16G6, afluidic material 1614 is then injected into the setting tool assembly 32and the packer assembly 36 through the longitudinal passages 1402 a,1404 b, 1406 b, 1408 b, 1504 b, 1550 a, and 1546 b of the tubularadaptor 1402, tubular upper mandrel 1404, tubular mandrel 1406, tubularstinger 1408, tubular upper mandrel 1504, tubular sliding sleeve valve1550, and tubular lower mandrel 1546, respectively. Because, the plug1606 is seated within and blocks the longitudinal passage 1564 a of thetubular plug seat 1564, the longitudinal passages 1504 b, 1550 a, and1546 b of the tubular upper mandrel 1504, tubular sliding sleeve valve1550, and tubular lower mandrel 1546 are pressurized thereby displacingthe tubular upper adaptor 1502 and tubular upper mandrel 1504 downwardlyuntil the end face of the tubular upper mandrel impacts the end face ofthe upper tubular spacer ring 1506.

In an exemplary embodiment, as illustrated in FIGS. 16H1 to 16H5, thesetting tool assembly 32 is brought back into engagement with the packerassembly 36 until the engagement shoulder 1408 e of the other end of thetubular stinger 1408 engages the collet fingers 1550 d of the end of thetubular sliding sleeve valve 1550. As a result, further downwarddisplacement of the tubular stinger 1408 displaces the tubular slidingsleeve valve 1550 downwardly until the radial flow ports, 1550 b and1550 c, of the tubular sliding sleeve valve are aligned with the flowports, 1546 e and 1546 f, of the tubular lower mandrel 1546. Ahardenable fluidic sealing material 1616 may then be injected into thesetting tool assembly 32 and the packer assembly 36 through thelongitudinal passages 1402 a, 1404 b, 1406 b, 1408 b, and 1550 a of thetubular adaptor 1402, tubular upper mandrel 1404, tubular mandrel 1406,tubular stinger 1408, and tubular sliding sleeve valve 1550,respectively. The hardenable fluidic sealing material may then flow outof the packer assembly 36 through the upper flow ports, 1558 d and 1558e, into the annulus between the expandable wellbore casing 100 and thewellbore 102.

The tubular sliding sleeve valve 1550 may then be returned to itsoriginal position, with the radial flow ports, 1550 b and 1550 c, of thetubular sliding sleeve valve out of alignment with the flow ports, 1546e and 1546 f, of the tubular lower mandrel 1546. The hardenable fluidicsealing material 1616 may then be allowed to cure before, during, orafter the continued operation of the system 10 to further radiallyexpand and plastically deform the expandable wellbore casing.

In an exemplary embodiment, the system 10 is provided as illustrated inAppendix A to the present application. FIGS. 1-10, 11, 11 a, 11 b, 11 c,11 d, 11 e, 11 f, 11 g, 11 h, 11 k, 11 l, 12 a, 12 b, 12 c, 13 a, 13 b,14, 15, 16 a, 16 b, 16 c, 16 d, 16 e, 16 f, 16 g, and 16 h of appendix Agenerally correspond to FIGS. 1-10, 11-1 to 11-2, 11A1 to 11A2, 11B1 to11B2, 11C, 11D, 11E, 11F, 11G, 11H, 11I, 11J, 11K, 11L, 12A1 to 12A4,12B, 12C1 to 12C4, 13A1 to 13A8, 13B1 to 13B7, 14A to 14C, 15-1 to 15-5,16A1 to 16A5, 16B1 to 16B5, 16C1 to 16C5, 16D1 to 16D5, 16E1 to 16E6,16F1 to 16F6, 16G1 to 16G6, and 16H1 to 16H5, respectively.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember, a cutting device for cutting the tubular member coupled to thesupport member, and an expansion device for radially expanding andplastically deforming the tubular member coupled to the support member.In an exemplary embodiment, the apparatus further includes a grippingdevice for gripping the tubular member coupled to the support member. Inan exemplary embodiment, the gripping device comprises a plurality ofmovable gripping elements. In an exemplary embodiment, the grippingelements are moveable in a radial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablein an axial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable in a radial and an axialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable from a first position to a secondposition; wherein in the first position, the gripping elements do notengage the tubular member; wherein in the second position, the grippingelements do engage the tubular member; and wherein, during the movementfrom the first position to the second position, the gripping elementsmove in a radial and an axial direction relative to the support member.In an exemplary embodiment, the gripping elements are moveable from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in a radial direction relative tothe support member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in an axial directionrelative to the support member. In an exemplary embodiment, if thetubular member is displaced in a first axial direction, the grippingdevice grips the tubular member; and, if the tubular member is displacedin a second axial direction, the gripping device does not grip thetubular member. In an exemplary embodiment, the gripping elements aremoveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; and

wherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a sealing device for sealingan interface with the tubular member coupled to the support member. Inan exemplary embodiment, the sealing device seals an annulus definesbetween the support member and the tubular member. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the apparatus further includes a packer assemblycoupled to the support member. In an exemplary embodiment, the packerassembly includes a packer; and a packer control device for controllingthe operation of the packer coupled to the support member. In anexemplary embodiment, the packer includes: a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member; and a sliding sleeve valve movably positionedwithin the passage of the support member. In an exemplary embodiment,the packer control device includes a support member; one or more dragblocks releasably coupled to the support member; and a stinger coupledto the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device includes: asupport member; one or more drag blocks releasably coupled to thesupport member; and a stinger coupled to the support member for engagingthe sliding sleeve valve. In an exemplary embodiment, the apparatusfurther includes an actuator for displacing the expansion devicerelative to the support member. In an exemplary embodiment, the actuatorincludes a first actuator for pulling the expansion device; and a secondactuator for pushing the expansion device. In an exemplary embodiment,the actuator includes means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, thefirst and second actuators include means for transferring torsionalloads between the support member and the expansion device. In anexemplary embodiment, the actuator includes a plurality of pistonspositioned within corresponding piston chambers. In an exemplaryembodiment, the cutting device includes a support member; and aplurality of movable cutting elements coupled to the support member. Inan exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the cutting elements between afirst position and a second position; wherein in the first position, thecutting elements do not engage the tubular member; and wherein in thesecond position, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements includes a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, theexpansion device includes a support member; and a plurality of movableexpansion elements coupled to the support member. In an exemplaryembodiment, apparatus further includes an actuator coupled to thesupport member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member, and wherein in thesecond position, the expansion elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the expansion elements include a first set ofexpansion elements; and a second set of expansion elements; wherein thefirst set of expansion elements are interleaved with the second set ofexpansion elements. In an exemplary embodiment, in the first position,the first set of expansion elements are not axially aligned with thesecond set of expansion elements. In an exemplary embodiment, in thesecond position, the first set of expansion elements are axially alignedwith the second set of expansion elements. In an exemplary embodiment,the expansion device includes an adjustable expansion device. In anexemplary embodiment, the expansion device includes a plurality ofexpansion devices. In an exemplary embodiment, at least one of theexpansion devices includes an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device includes a supportmember; and a plurality of movable expansion elements coupled to thesupport member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember, an expansion device for radially expanding and plasticallydeforming the tubular member coupled to the support member, and anactuator coupled to the support member for displacing the expansiondevice relative to the support member. In an exemplary embodiment, theapparatus further includes a cutting device coupled to the supportmember for cutting the tubular member. In an exemplary embodiment, thecutting device includes a support member; and a plurality of movablecutting elements coupled to the support member. In an exemplaryembodiment, the apparatus further includes an actuator coupled to thesupport member for moving the cutting elements between a first positionand a second position; wherein in the first position, the cuttingelements do not engage the tubular member; and wherein in the secondposition, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements include a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, theapparatus further includes a gripping device for gripping the tubularmember coupled to the support member. In an exemplary embodiment, thegripping device includes a plurality of movable gripping elements. In anexemplary embodiment, the gripping elements are moveable in a radialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable in an axial direction relative to thesupport member. In an exemplary embodiment, the gripping elements aremoveable in a radial and an axial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radial and anaxial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable from a first position toa second position; wherein in the first position, the gripping elementsdo not engage the tubular member; wherein in the second position, thegripping elements do engage the tubular member; and wherein, during themovement from the first position to the second position, the grippingelements move in a radial direction relative to the support member. Inan exemplary embodiment, the gripping elements are moveable from a firstposition to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in an axial direction relative tothe support member. In an exemplary embodiment, if the tubular member isdisplaced in a first axial direction, the gripping device grips thetubular member; and wherein, if the tubular member is displaced in asecond axial direction, the gripping device does not grip the tubularmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a sealing device for sealingan interface with the tubular member coupled to the support member. Inan exemplary embodiment, the sealing device seals an annulus definesbetween the support member and the tubular member. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the apparatus further includes a packer assemblycoupled to the support member. In an exemplary embodiment, the packerassembly includes a packer; and a packer control device for controllingthe operation of the packer coupled to the support member. In anexemplary embodiment, the packer includes a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member; and a sliding sleeve valve movably positionedwithin the passage of the support member. In an exemplary embodiment,the packer control device includes a support member; one or more dragblocks releasably coupled to the support member; and a stinger coupledto the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device comprises: asupport member; one or more drag blocks releasably coupled to thesupport member; and a stinger coupled to the support member for engagingthe sliding sleeve valve. In an exemplary embodiment, the expansiondevice includes a support member; and a plurality of movable expansionelements coupled to the support member. In an exemplary embodiment, theapparatus further includes an actuator coupled to the support member formoving the expansion elements between a first position and a secondposition; wherein in the first position, the expansion elements do notengage the tubular member; and wherein in the second position, theexpansion elements engage the tubular member. In an exemplaryembodiment, the apparatus further includes a sensor coupled to thesupport member for sensing the internal diameter of the tubular member.In an exemplary embodiment, the sensor prevents the expansion elementsfrom being moved to the second position if the internal diameter of thetubular member is less than a predetermined value. In an exemplaryembodiment, the expansion elements include a first set of expansionelements; and a second set of expansion elements; wherein the first setof expansion elements are interleaved with the second set of expansionelements. In an exemplary embodiment, the in the first position, thefirst set of expansion elements are not axially aligned with the secondset of expansion elements. In an exemplary embodiment, in the secondposition, the first set of expansion elements are axially aligned withthe second set of expansion elements. In an exemplary embodiment, theexpansion device includes an adjustable expansion device. In anexemplary embodiment, the expansion device includes a plurality ofexpansion devices. In an exemplary embodiment, at least one of theexpansion devices includes an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device includes a supportmember; and a plurality of movable expansion elements coupled to thesupport member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember; an expansion device for radially expanding and plasticallydeforming the tubular member coupled to the support member; and asealing assembly for sealing an annulus defined between the supportmember and the tubular member. In an exemplary embodiment, the apparatusfurther includes a gripping device for gripping the tubular membercoupled to the support member. In an exemplary embodiment, the grippingdevice includes a plurality of movable gripping elements. In anexemplary embodiment, the gripping elements are moveable in a radialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable in an axial direction relative to thesupport member. In an exemplary embodiment, the gripping elements aremoveable in a radial and an axial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radial and anaxial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable from a first position toa second position; wherein in the first position, the gripping elementsdo not engage the tubular member; wherein in the second position, thegripping elements do engage the tubular member; and wherein, during themovement from the first position to the second position, the grippingelements move in a radial direction relative to the support member. Inan exemplary embodiment, the gripping elements are moveable from a firstposition to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in an axial direction relative tothe support member. In an exemplary embodiment, the if the tubularmember is displaced in a first axial direction, the gripping devicegrips the tubular member; and wherein, if the tubular member isdisplaced in a second axial direction, the gripping device does not gripthe tubular member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the apparatus further includes a packer assemblycoupled to the support member. In an exemplary embodiment, the packerassembly includes a packer; and a packer control device for controllingthe operation of the packer coupled to the support member. In anexemplary embodiment, the packer includes a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member; and a sliding sleeve valve movably positionedwithin the passage of the support member. In an exemplary embodiment,the packer control device includes a support member; one or more dragblocks releasably coupled to the support member; and a stinger coupledto the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device includes a supportmember; one or more drag blocks releasably coupled to the supportmember; and a stinger coupled to the support member for engaging thesliding sleeve valve. In an exemplary embodiment, the apparatus furtherincludes an actuator for displacing the expansion device relative to thesupport member. In an exemplary embodiment, the actuator includes afirst actuator for pulling the expansion device; and a second actuatorfor pushing the expansion device. In an exemplary embodiment, theactuator includes means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, thefirst and second actuators comprise means for transferring torsionalloads between the support member and the expansion device. In anexemplary embodiment, the actuator includes a plurality of pistonspositioned within corresponding piston chambers. In an exemplaryembodiment, the cutting device includes a support member; and aplurality of movable cutting elements coupled to the support member. Inan exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the cutting elements between afirst position and a second position; wherein in the first position, thecutting elements do not engage the tubular member; and wherein in thesecond position, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements include a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, theexpansion device includes a support member; and a plurality of movableexpansion elements coupled to the support member. In an exemplaryembodiment, the apparatus further includes an actuator coupled to thesupport member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member; and wherein in thesecond position, the expansion elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the expansion elements includes a first set ofexpansion elements; and a second set of expansion elements; wherein thefirst set of expansion elements are interleaved with the second set ofexpansion elements. In an exemplary embodiment, in the first position,the first set of expansion elements are not axially aligned with thesecond set of expansion elements. In an exemplary embodiment, in thesecond position, the first set of expansion elements are axially alignedwith the second set of expansion elements. In an exemplary embodiment,the expansion device includes an adjustable expansion device. In anexemplary embodiment, the expansion device includes a plurality ofexpansion devices. In an exemplary embodiment, at least one of theexpansion devices includes an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device includes a supportmember; and a plurality of movable expansion elements coupled to thesupport member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember; a first expansion device for radially expanding and plasticallydeforming the tubular member coupled to the support member; and a secondexpansion device for radially expanding and plastically deforming thetubular member coupled to the support member. In an exemplaryembodiment, the apparatus further includes a gripping device forgripping the tubular member coupled to the support member. In anexemplary embodiment, the gripping device includes a plurality ofmovable gripping elements. In an exemplary embodiment, the grippingelements are moveable in a radial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablein an axial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable in a radial and an axialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable from a first position to a secondposition; wherein in the first position, the gripping elements do notengage the tubular member; wherein in the second position, the grippingelements do engage the tubular member; and wherein, during the movementfrom the first position to the second position, the gripping elementsmove in a radial and an axial direction relative to the support member.In an exemplary embodiment, the gripping elements are moveable from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in a radial direction relative tothe support member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in an axial directionrelative to the support member. In an exemplary embodiment, if thetubular member is displaced in a first axial direction, the grippingdevice grips the tubular member; and wherein, if the tubular member isdisplaced in a second axial direction, the gripping device does not gripthe tubular member, In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a sealing device for sealingan interface with the tubular member coupled to the support member. Inan exemplary embodiment, the sealing device seals an annulus definesbetween the support member and the tubular member. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the apparatus further includes a packer assemblycoupled to the support member. In an exemplary embodiment, the packerassembly includes a packer; and a packer control device for controllingthe operation of the packer coupled to the support member. In anexemplary embodiment, the packer includes a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member; and a sliding sleeve valve movably positionedwithin the passage of the support member. In an exemplary embodiment,the packer control device includes a support member; one or more dragblocks releasably coupled to the support member; and a stinger coupledto the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device comprises: asupport member; one or more drag blocks releasably coupled to thesupport member; and a stinger coupled to the support member for engagingthe sliding sleeve valve. In an exemplary embodiment, the apparatusfurther includes an actuator for displacing the expansion devicerelative to the support member. In an exemplary embodiment, the actuatorincludes a first actuator for pulling the expansion device; and a secondactuator for pushing the expansion device. In an exemplary embodiment,the actuator includes means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, thefirst and second actuators include means for transferring torsionalloads between the support member and the expansion device. In anexemplary embodiment, the actuator includes a plurality of pistonspositioned within corresponding piston chambers. In an exemplaryembodiment, the apparatus further includes a cutting device for cuttingthe tubular member coupled to the support member. In an exemplaryembodiment, the cutting device includes a support member; and aplurality of movable cutting elements coupled to the support member. Inan exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the cutting elements between afirst position and a second position; wherein in the first position, thecutting elements do not engage the tubular member; and wherein in thesecond position, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements include a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, at least oneof the first second expansion devices include a support member; and aplurality of movable expansion elements coupled to the support member.In an exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the expansion elements betweena first position and a second position; wherein in the first position,the expansion elements do not engage the tubular member; and wherein inthe second position, the expansion elements engage the tubular member.In an exemplary embodiment, the apparatus further includes a sensorcoupled to the support member for sensing the internal diameter of thetubular member. In an exemplary embodiment, the sensor prevents theexpansion elements from being moved to the second position if theinternal diameter of the tubular member is less than a predeterminedvalue. In an exemplary embodiment, the expansion elements include afirst set of expansion elements; and a second set of expansion elements;wherein the first set of expansion elements are interleaved with thesecond set of expansion elements. In an exemplary embodiment, in thefirst position, the first set of expansion elements are not axiallyaligned with the second set of expansion elements. In an exemplaryembodiment, in the second position, the first set of expansion elementsare axially aligned with the second set of expansion elements. In anexemplary embodiment, at least one of the first and second expansiondevices comprise a plurality of expansion devices. In an exemplaryembodiment, at least one of the first and second expansion devicecomprise an adjustable expansion device. In an exemplary embodiment, theadjustable expansion device includes a support member; and a pluralityof movable expansion elements coupled to the support member. In anexemplary embodiment, the apparatus further includes an actuator coupledto the support member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member; and wherein in thesecond position, the expansion elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the expansion elements include a first set ofexpansion elements; and a second set of expansion elements; wherein thefirst set of expansion elements are interleaved with the second set ofexpansion elements. In an exemplary embodiment, in the first position,the first set of expansion elements are not axially aligned with thesecond set of expansion elements. In an exemplary embodiment, in thesecond position, the first set of expansion elements are axially alignedwith the second set of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember; an expansion device for radially expanding and plasticallydeforming the tubular member coupled to the support member; and a packercoupled to the support member. In an exemplary embodiment, the apparatusfurther includes a gripping device for gripping the tubular membercoupled to the support member. In an exemplary embodiment, the grippingdevice comprises a plurality of movable gripping elements. In anexemplary embodiment, the gripping elements are moveable in a radialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable in an axial direction relative to thesupport member. In an exemplary embodiment, the gripping elements aremoveable in a radial and an axial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radial and anaxial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable from a first position toa second position; wherein in the first position, the gripping elementsdo not engage the tubular member; wherein in the second position, thegripping elements do engage the tubular member; and wherein, during themovement from the first position to the second position, the grippingelements move in a radial direction relative to the support member. Inan exemplary embodiment, the gripping elements are moveable from a firstposition to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in an axial direction relative tothe support member. In an exemplary embodiment, if the tubular member isdisplaced in a first axial direction, the gripping device grips thetubular member; and wherein, if the tubular member is displaced in asecond axial direction, the gripping device does not grip the tubularmember. In an exemplary embodiment, the gripping elements are moveablefrom a first position to a second position; wherein in the firstposition, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the apparatus further includes a sealing device for sealingan interface with the tubular member coupled to the support member. Inan exemplary embodiment, the sealing device seals an annulus definesbetween the support member and the tubular member. In an exemplaryembodiment, the apparatus further includes a locking device for lockingthe position of the tubular member relative to the support member. In anexemplary embodiment, the packer assembly includes a packer; and apacker control device for controlling the operation of the packercoupled to the support member. In an exemplary embodiment, the packerincludes a support member defining a passage; a shoe comprising a floatvalve coupled to an end of the support member; one or more compressiblepacker elements movably coupled to the support member; and a slidingsleeve valve movably positioned within the passage of the supportmember. In an exemplary embodiment, the packer control device includes asupport member; one or more drag blocks releasably coupled to thesupport member; and a stinger coupled to the support member for engagingthe packer. In an exemplary embodiment, the packer includes a supportmember defining a passage; a shoe comprising a float valve coupled to anend of the support member; one or more compressible packer elementsmovably coupled to the support member; and a sliding sleeve valvepositioned within the passage of the support member; and wherein thepacker control device includes a support member; one or more drag blocksreleasably coupled to the support member; and a stinger coupled to thesupport member for engaging the sliding sleeve valve. In an exemplaryembodiment, the apparatus further includes an actuator for displacingthe expansion device relative to the support member. In an exemplaryembodiment, the actuator includes a first actuator for pulling theexpansion device; and a second actuator for pushing the expansiondevice. In an exemplary embodiment, the actuator includes means fortransferring torsional loads between the support member and theexpansion device. In an exemplary embodiment, the first and secondactuators include means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, theactuator includes a plurality of pistons positioned within correspondingpiston chambers. In an exemplary embodiment, the apparatus furtherincludes a cutting device coupled to the support member for cutting thetubular member. In an exemplary embodiment, the cutting device includesa support member; and a plurality of movable cutting elements coupled tothe support member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving thecutting elements between a first position and a second position; whereinin the first position, the cutting elements do not engage the tubularmember; and wherein in the second position, the cutting elements engagethe tubular member. In an exemplary embodiment, the apparatus furtherincludes a sensor coupled to the support member for sensing the internaldiameter of the tubular member. In an exemplary embodiment, the sensorprevents the cutting elements from being moved to the second position ifthe internal diameter of the tubular member is less than a predeterminedvalue. In an exemplary embodiment, the cutting elements include a firstset of cutting elements; and a second set of cutting elements; whereinthe first set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cutting elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, theexpansion device includes a support member; and a plurality of movableexpansion elements coupled to the support member. In an exemplaryembodiment, the apparatus further includes an actuator coupled to thesupport member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member; and wherein in thesecond position, the expansion elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the expansion elements include a first set ofexpansion elements; and a second set of expansion elements; wherein thefirst set of expansion elements are interleaved with the second set ofexpansion elements. In an exemplary embodiment, in the first position,the first set of expansion elements are not axially aligned with thesecond set of expansion elements. In an exemplary embodiment, in thesecond position, the first set of expansion elements are axially alignedwith the second set of expansion elements. In an exemplary embodiment,the expansion device includes an adjustable expansion device. In anexemplary embodiment, the expansion device includes a plurality ofexpansion devices. In an exemplary embodiment, at least one of theexpansion devices comprises an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device includes a supportmember; and a plurality of movable expansion elements coupled to thesupport member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes a supportmember; a cutting device for cutting the tubular member coupled to thesupport member; a gripping device for gripping the tubular membercoupled to the support member; a sealing device for sealing an interfacewith the tubular member coupled to the support member; a locking devicefor locking the position of the tubular member relative to the supportmember; a first adjustable expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;a second adjustable expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;a packer coupled to the support member; and an actuator for displacingone or more of the sealing assembly, first and second adjustableexpansion devices, and packer relative to the support member. In anexemplary embodiment, the gripping device includes a plurality ofmovable gripping elements. In an exemplary embodiment, the grippingelements are moveable in a radial direction relative to the supportmember. In an exemplary embodiment, the gripping elements are moveablein an axial direction relative to the support member. In an exemplaryembodiment, the gripping elements are moveable in a radial and an axialdirection relative to the support member. In an exemplary embodiment,the gripping elements are moveable from a first position to a secondposition; wherein in the first position, the gripping elements do notengage the tubular member; wherein in the second position, the grippingelements do engage the tubular member; and wherein, during the movementfrom the first position to the second position, the gripping elementsmove in a radial and an axial direction relative to the support member.In an exemplary embodiment, the gripping elements are moveable from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in a radial direction relative tothe support member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in an axial directionrelative to the support member. In an exemplary embodiment, if thetubular member is displaced in a first axial direction, the grippingdevice grips the tubular member; and wherein, if the tubular member isdisplaced in a second axial direction, the gripping device does not gripthe tubular member. In an exemplary embodiment, the gripping elementsare moveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, the gripping elements are biased to remainin the first position. In an exemplary embodiment, the gripping devicefurther includes an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator. In an exemplaryembodiment, the sealing device seals an annulus defines between thesupport member and the tubular member. In an exemplary embodiment, thepacker assembly includes a packer; and a packer control device forcontrolling the operation of the packer coupled to the support member.In an exemplary embodiment, the packer includes a support memberdefining a passage; a shoe comprising a float valve coupled to an end ofthe support member; one or more compressible packer elements movablycoupled to the support member; and a sliding sleeve valve movablypositioned within the passage of the support member. In an exemplaryembodiment, the packer control device includes a support member; one ormore drag blocks releasably coupled to the support member; and a stingercoupled to the support member for engaging the packer. In an exemplaryembodiment, the packer includes a support member defining a passage; ashoe comprising a float valve coupled to an end of the support member;one or more compressible packer elements movably coupled to the supportmember; and a sliding sleeve valve positioned within the passage of thesupport member; and wherein the packer control device includes a supportmember; one or more drag blocks releasably coupled to the supportmember; and a stinger coupled to the support member for engaging thesliding sleeve valve. In an exemplary embodiment, the actuator includesa first actuator for pulling the expansion device; and a second actuatorfor pushing the expansion device. In an exemplary embodiment, theactuator includes means for transferring torsional loads between thesupport member and the expansion device. In an exemplary embodiment, thefirst and second actuators include means for transferring torsionalloads between the support member and the expansion device. In anexemplary embodiment, the actuator includes a plurality of pistonspositioned within corresponding piston chambers. In an exemplaryembodiment, the cutting device includes a support member; and aplurality of movable cutting elements coupled to the support member. Inan exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the cutting elements between afirst position and a second position; wherein in the first position, thecutting elements do not engage the tubular member; and wherein in thesecond position, the cutting elements engage the tubular member. In anexemplary embodiment, the apparatus further includes a sensor coupled tothe support member for sensing the internal diameter of the tubularmember. In an exemplary embodiment, the sensor prevents the cuttingelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the cutting elements include a first set ofcutting elements; and a second set of cutting elements; wherein thefirst set of cutting elements are interleaved with the second set ofcutting elements. In an exemplary embodiment, in the first position, thefirst set of cutting elements are not axially aligned with the secondset of cutting elements. In an exemplary embodiment, in the secondposition, the first set of cuffing elements are axially aligned with thesecond set of cutting elements. In an exemplary embodiment, at least oneof the adjustable expansion devices include a support member; and aplurality of movable expansion elements coupled to the support member.In an exemplary embodiment, the apparatus further includes an actuatorcoupled to the support member for moving the expansion elements betweena first position and a second position; wherein in the first position,the expansion elements do not engage the tubular member; and wherein inthe second position, the expansion elements engage the tubular member.In an exemplary embodiment, the apparatus further includes a sensorcoupled to the support member for sensing the internal diameter of thetubular member. In an exemplary embodiment, the sensor prevents theexpansion elements from being moved to the second position if theinternal diameter of the tubular member is less than a predeterminedvalue. In an exemplary embodiment, the expansion elements include afirst set of expansion elements; and a second set of expansion elements;wherein the first set of expansion elements are interleaved with thesecond set of expansion elements. In an exemplary embodiment, in thefirst position, the first set of expansion elements are not axiallyaligned with the second set of expansion elements. In an exemplaryembodiment, in in the second position, the first set of expansionelements are axially aligned with the second set of expansion elements.In an exemplary embodiment, at least one of the adjustable expansiondevices comprise a plurality of expansion devices. In an exemplaryembodiment, at least one of the adjustable expansion devices include asupport member; and a plurality of movable expansion elements coupled tothe support member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theexpansion elements between a first position and a second position;wherein in the first position, the expansion elements do not engage thetubular member; and wherein in the second position, the expansionelements engage the tubular member. In an exemplary embodiment, theapparatus further includes a sensor coupled to the support member forsensing the internal diameter of the tubular member. In an exemplaryembodiment, the sensor prevents the expansion elements from being movedto the second position if the internal diameter of the tubular member isless than a predetermined value. In an exemplary embodiment, theexpansion elements include a first set of expansion elements; and asecond set of expansion elements; wherein the first set of expansionelements are interleaved with the second set of expansion elements. Inan exemplary embodiment, in the first position, the first set ofexpansion elements are not axially aligned with the second set ofexpansion elements. In an exemplary embodiment, in the second position,the first set of expansion elements are axially aligned with the secondset of expansion elements.

An apparatus for cutting a tubular member has been described thatincludes a support member; and a plurality of movable cutting elementscoupled to the support member. In an exemplary embodiment, the apparatusfurther includes an actuator coupled to the support member for movingthe cutting elements between a first position and a second position;wherein in the first position, the cutting elements do not engage thetubular member; and wherein in the second position, the cutting elementsengage the tubular member. In an exemplary embodiment, the apparatusfurther includes a sensor coupled to the support member for sensing theinternal diameter of the tubular member. In an exemplary embodiment, thesensor prevents the cutting elements from being moved to the secondposition if the internal diameter of the tubular member is less than apredetermined value. In an exemplary embodiment, the cutting elementsinclude a first set of cutting elements; and a second set of cuttingelements; wherein the first set of cutting elements are interleaved withthe second set of cutting elements. In an exemplary embodiment, in thefirst position, the first set of cutting elements are not axiallyaligned with the second set of cutting elements. In an exemplaryembodiment, in the second position, the first set of cutting elementsare axially aligned with the second set of cutting elements.

An apparatus for engaging a tubular member has been described thatincludes a support member; and a plurality of movable elements coupledto the support member. In an exemplary embodiment, the apparatus furtherincludes an actuator coupled to the support member for moving theelements between a first position and a second position; wherein in thefirst position, the elements do not engage the tubular member; andwherein in the second position, the elements engage the tubular member.In an exemplary embodiment, the apparatus further includes a sensorcoupled to the support member for sensing the internal diameter of thetubular member. In an exemplary embodiment, the sensor prevents theelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. In anexemplary embodiment, the elements include a first set of elements; anda second set of elements; wherein the first set of elements areinterleaved with the second set of elements. In an exemplary embodiment,in the first position, the first set of elements are not axially alignedwith the second set of elements. In an exemplary embodiment, in thesecond position, the first set of elements are axially aligned with thesecond set of elements.

An apparatus for gripping a tubular member has been described thatincludes a plurality of movable gripping elements. In an exemplaryembodiment, the gripping elements are moveable in a radial direction. Inan exemplary embodiment, the gripping elements are moveable in an axialdirection. In an exemplary embodiment, the gripping elements aremoveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radial and anaxial direction. In an exemplary embodiment, the gripping elements aremoveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in a radialdirection. In an exemplary embodiment, the gripping elements aremoveable from a first position to a second position; wherein in thefirst position, the gripping elements do not engage the tubular member;wherein in the second position, the gripping elements do engage thetubular member; and wherein, during the movement from the first positionto the second position, the gripping elements move in an axialdirection. In an exemplary embodiment, in a first axial direction, thegripping device grips the tubular member; and wherein, in a second axialdirection, the gripping device does not grip the tubular member. In anexemplary embodiment, the apparatus further includes an actuator formoving the gripping elements. In an exemplary embodiment, the grippingelements include a plurality of separate and distinct gripping elements.

An actuator has been described that includes a tubular housing; atubular piston rod movably coupled to and at least partially positionedwithin the housing; a plurality of annular piston chambers defined bythe tubular housing and the tubular piston rod; and a plurality oftubular pistons coupled to the tubular piston rod, each tubular pistonmovably positioned within a corresponding annular piston chamber. In anexemplary embodiment, the actuator further includes means fortransmitting torsional loads between the tubular housing and the tubularpiston rod.

An apparatus for controlling a packer has been described that includes atubular support member; one or more drag blocks releasably coupled tothe tubular support member; and a tubular stinger coupled to the tubularsupport member for engaging the packer. In an exemplary embodiment, theapparatus further includes a tubular sleeve coupled to the drag blocks.In an exemplary embodiment, the tubular support member includes one ormore axially aligned teeth for engaging the packer.

A packer has been described that includes a support member defining apassage; a shoe comprising a float valve coupled to an end of thesupport member; one or more compressible packer elements movably coupledto the support member; and a sliding sleeve valve movably positionedwithin the passage of the support member.

A method of radially expanding and plastically deforming an expandabletubular member within a borehole having a preexisting wellbore casinghas been described that includes positioning the tubular member withinthe borehole in overlapping relation to the wellbore casing; radiallyexpanding and plastically deforming a portion of the tubular member toform a bell section; and radially expanding and plastically deforming aportion of the tubular member above the bell section comprising aportion of the tubular member that overlaps with the wellbore casing;wherein the inside diameter of the bell section is greater than theinside diameter of the radially expanded and plastically deformedportion of the tubular member above the bell section. In an exemplaryembodiment, radially expanding and plastically deforming a portion ofthe tubular member to form a bell section includes positioning anadjustable expansion device within the expandable tubular member;supporting the expandable tubular member and the adjustable expansiondevice within the borehole; lowering the adjustable expansion device outof the expandable tubular member; increasing the outside dimension ofthe adjustable expansion device; and displacing the adjustable expansiondevice upwardly relative to the expandable tubular member n times toradially expand and plastically deform n portions of the expandabletubular member, wherein n is greater than or equal to 1.

A method for forming a mono diameter wellbore casing has been describedthat includes positioning an adjustable expansion device within a firstexpandable tubular member; supporting the first expandable tubularmember and the adjustable expansion device within a borehole; loweringthe adjustable expansion device out of the first expandable tubularmember; increasing the outside dimension of the adjustable expansiondevice; displacing the adjustable expansion device upwardly relative tothe first expandable tubular member m times to radially expand andplastically deform m portions of the first expandable tubular memberwithin the borehole; positioning the adjustable expansion device withina second expandable tubular member; supporting the second expandabletubular member and the adjustable expansion device within the boreholein overlapping relation to the first expandable tubular member; loweringthe adjustable expansion device out of the second expandable tubularmember; increasing the outside dimension of the adjustable expansiondevice; and displacing the adjustable expansion device upwardly relativeto the second expandable tubular member n times to radially expand andplastically deform n portions of the second expandable tubular memberwithin the borehole.

A method for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includespositioning an adjustable expansion device within the expandable tubularmember; supporting the expandable tubular member and the adjustableexpansion device within the borehole; lowering the adjustable expansiondevice out of the expandable tubular member; increasing the outsidedimension of the adjustable expansion device; displacing the adjustableexpansion mandrel upwardly relative to the expandable tubular member ntimes to radially expand and plastically deform n portions of theexpandable tubular member within the borehole; and pressurizing aninterior region of the expandable tubular member above the adjustableexpansion device during the radial expansion and plastic deformation ofthe expandable tubular member within the borehole.

A method for forming a mono diameter wellbore casing has been describedthat includes positioning an adjustable expansion device within a firstexpandable tubular member; supporting the first expandable tubularmember and the adjustable expansion device within a borehole; loweringthe adjustable expansion device out of the first expandable tubularmember; increasing the outside dimension of the adjustable expansiondevice; displacing the adjustable expansion device upwardly relative tothe first expandable tubular member m times to radially expand andplastically deform m portions of the first expandable tubular memberwithin the borehole; pressurizing an interior region of the firstexpandable tubular member above the adjustable expansion device duringthe radial expansion and plastic deformation of the first expandabletubular member within the borehole; positioning the adjustable expansionmandrel within a second expandable tubular member; supporting the secondexpandable tubular member and the adjustable expansion mandrel withinthe borehole in overlapping relation to the first expandable tubularmember, lowering the adjustable expansion mandrel out of the secondexpandable tubular member; increasing the outside dimension of theadjustable expansion mandrel; displacing the adjustable expansionmandrel upwardly relative to the second expandable tubular member ntimes to radially expand and plastically deform n portions of the secondexpandable tubular member within the borehole; and pressurizing aninterior region of the second expandable tubular member above theadjustable expansion mandrel during the radial expansion and plasticdeformation of the second expandable tubular member within the borehole.

A method for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includespositioning first and second adjustable expansion devices within theexpandable tubular member; supporting the expandable tubular member andthe first and second adjustable expansion devices within the borehole;lowering the first adjustable expansion device out of the expandabletubular member; increasing the outside dimension of the first adjustableexpansion device; displacing the first adjustable expansion deviceupwardly relative to the expandable tubular member to radially expandand plastically deform a lower portion of the expandable tubular member;displacing the first adjustable expansion device and the secondadjustable expansion device downwardly relative to the expandabletubular member; decreasing the outside dimension of the first adjustableexpansion device and increasing the outside dimension of the secondadjustable expansion device; displacing the second adjustable expansiondevice upwardly relative to the expandable tubular member to radiallyexpand and plastically deform portions of the expandable tubular memberabove the lower portion of the expandable tubular member; wherein theoutside dimension of the first adjustable expansion device is greaterthan the outside dimension of the second adjustable expansion device.

A method for forming a mono diameter wellbore casing has been describedthat includes positioning first and second adjustable expansion deviceswithin a first expandable tubular member; supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within a borehole; lowering the first adjustable expansiondevice out of the first expandable tubular member; increasing theoutside dimension of the first adjustable expansion device; displacingthe first adjustable expansion device upwardly relative to the firstexpandable tubular member to radially expand and plastically deform alower portion of the first expandable tubular member; displacing thefirst adjustable expansion device and the second adjustable expansiondevice downwardly relative to the first expandable tubular member;decreasing the outside dimension of the first adjustable expansiondevice and increasing the outside dimension of the second adjustableexpansion device; displacing the second adjustable expansion deviceupwardly relative to the first expandable tubular member to radiallyexpand and plastically deform portions of the first expandable tubularmember above the lower portion of the expandable tubular member;positioning first and second adjustable expansion devices within asecond expandable tubular member; supporting the first expandabletubular member and the first and second adjustable expansion deviceswithin the borehole in overlapping relation to the first expandabletubular member; lowering the first adjustable expansion device out ofthe second expandable tubular member; increasing the outside dimensionof the first adjustable expansion device; displacing the firstadjustable expansion device upwardly relative to the second expandabletubular member to radially expand and plastically deform a lower portionof the second expandable tubular member; displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the second expandable tubular member; decreasing the outsidedimension of the first adjustable expansion device and increasing theoutside dimension of the second adjustable expansion device; anddisplacing the second adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform portions of the second expandable tubular member above the lowerportion of the second expandable tubular member; wherein the outsidedimension of the first adjustable expansion device is greater than theoutside dimension of the second adjustable expansion device.

A method for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includespositioning first and second adjustable expansion devices within theexpandable tubular member; supporting the expandable tubular member andthe first and second adjustable expansion devices within the borehole;lowering the first adjustable expansion device out of the expandabletubular member; increasing the outside dimension of the first adjustableexpansion device; displacing the first adjustable expansion deviceupwardly relative to the expandable tubular member to radially expandand plastically deform a lower portion of the expandable tubular member;pressurizing an interior region of the expandable tubular member abovethe first adjustable expansion device during the radial expansion of thelower portion of the expandable tubular member by the first adjustableexpansion device; displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to theexpandable tubular member; decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; displacing the second adjustableexpansion device upwardly relative to the expandable tubular member toradially expand and plastically deform portions of the expandabletubular member above the lower portion of the expandable tubular member;and pressurizing an interior region of the expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the expandable tubular member above the lower portionof the expandable tubular member by the second adjustable expansiondevice; wherein the outside dimension of the first adjustable expansiondevice is greater than the outside dimension of the second adjustableexpansion device.

A method for forming a mono diameter wellbore casing has been describedthat includes positioning first and second adjustable expansion deviceswithin a first expandable tubular member; supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within a borehole; lowering the first adjustable expansiondevice out of the first expandable tubular member; increasing theoutside dimension of the first adjustable expansion device; displacingthe first adjustable expansion device upwardly relative to the firstexpandable tubular member to radially expand and plastically deform alower portion of the first expandable tubular member; pressurizing aninterior region of the first expandable tubular member above the firstadjustable expansion device during the radial expansion of the lowerportion of the first expandable tubular member by the first adjustableexpansion device; displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the firstexpandable tubular member; decreasing the outside dimension of the firstadjustable expansion device and increasing the outside dimension of thesecond adjustable expansion device; displacing the second adjustableexpansion device upwardly relative to the first expandable tubularmember to radially expand and plastically deform portions of the firstexpandable tubular member above the lower portion of the expandabletubular member; pressurizing an interior region of the first expandabletubular member above the second adjustable expansion device during theradial expansion of the portions of the first expandable tubular memberabove the lower portion of the first expandable tubular member by thesecond adjustable expansion device; positioning first and secondadjustable expansion devices within a second expandable tubular member,supporting the first expandable tubular member and the first and secondadjustable expansion devices within the borehole in overlapping relationto the first expandable tubular member; lowering the first adjustableexpansion device out of the second expandable tubular member; increasingthe outside dimension of the first adjustable expansion device;displacing the first adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform a lower portion of the second expandable tubular member;pressurizing an interior region of the second expandable tubular memberabove the first adjustable expansion device during the radial expansionof the lower portion of the second expandable tubular member by thefirst adjustable expansion device; displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the second expandable tubular member; decreasing the outsidedimension of the first adjustable expansion device and increasing theoutside dimension of the second adjustable expansion device; displacingthe second adjustable expansion device upwardly relative to the secondexpandable tubular member to radially expand and plastically deformportions of the second expandable tubular member above the lower portionof the second expandable tubular member; and pressurizing an interiorregion of the second expandable tubular member above the secondadjustable expansion device during the radial expansion of the portionsof the second expandable tubular member above the lower portion of thesecond expandable tubular member by the second adjustable expansiondevice; wherein the outside dimension of the first adjustable expansiondevice is greater than the outside dimension of the second adjustableexpansion device.

A method for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includessupporting the expandable tubular member, an hydraulic actuator, and anadjustable expansion device within the borehole; increasing the size ofthe adjustable expansion device; and displacing the adjustable expansiondevice upwardly relative to the expandable tubular member using thehydraulic actuator to radially expand and plastically deform a portionof the expandable tubular member. In an exemplary embodiment, the methodfurther includes reducing the size of the adjustable expansion deviceafter the portion of the expandable tubular member has been radiallyexpanded and plastically deformed. In an exemplary embodiment, themethod further includes fluidicly sealing the radially expanded andplastically deformed end of the expandable tubular member after reducingthe size of the adjustable expansion device. In an exemplary embodiment,the method further includes permitting the position of the expandabletubular member to float relative to the position of the hydraulicactuator after fluidicly sealing the radially expanded and plasticallydeformed end of the expandable tubular member. In an exemplaryembodiment, the method further includes injecting a hardenable fluidicsealing material into an annulus between the expandable tubular memberand a preexisting structure after permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator. In an exemplary embodiment, the method furtherincludes increasing the size of the adjustable expansion device afterpermitting the position of the expandable tubular member to floatrelative to the position of the hydraulic actuator. In an exemplaryembodiment, the method further includes displacing the adjustableexpansion cone upwardly relative to the expandable tubular member toradially expand and plastically deform another portion of the expandabletubular member. In an exemplary embodiment, the method further includesif the end of the other portion of the expandable tubular memberoverlaps with a preexisting structure, then not permitting the positionof the expandable tubular member to float relative to the position ofthe hydraulic actuator; and displacing the adjustable expansion coneupwardly relative to the expandable tubular member using the hydraulicactuator to radially expand and plastically deform the end of the otherportion of the expandable tubular member that overlaps with thepreexisting structure.

A method for forming a mono diameter wellbore casing within a boreholethat includes a preexisting wellbore casing has been described thatincludes supporting the expandable tubular member, an hydraulicactuator, and an adjustable expansion device within the borehole;increasing the size of the adjustable expansion device; displacing theadjustable expansion device upwardly relative to the expandable tubularmember using the hydraulic actuator to radially expand and plasticallydeform a portion of the expandable tubular member; and displacing theadjustable expansion device upwardly relative to the expandable tubularmember to radially expand and plastically deform the remaining portionof the expandable tubular member and a portion of the preexistingwellbore casing that overlaps with an end of the remaining portion ofthe expandable tubular member. In an exemplary embodiment, the methodfurther includes reducing the size of the adjustable expansion deviceafter the portion of the expandable tubular member has been radiallyexpanded and plastically deformed. In an exemplary embodiment, themethod further includes fluidicly sealing the radially expanded andplastically deformed end of the expandable tubular member after reducingthe size of the adjustable expansion device. In an exemplary embodiment,the method further includes permitting the position of the expandabletubular member to float relative to the position of the hydraulicactuator after fluidicly sealing the radially expanded and plasticallydeformed end of the expandable tubular member. In an exemplaryembodiment, the method further includes injecting a hardenable fluidicsealing material into an annulus between the expandable tubular memberand the borehole after permitting the position of the expandable tubularmember to float relative to the position of the hydraulic actuator. Inan exemplary embodiment, the method further includes increasing the sizeof the adjustable expansion device after permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator. In an exemplary embodiment, the method furtherincludes displacing the adjustable expansion cone upwardly relative tothe expandable tubular member to radially expand and plastically deformthe remaining portion of the expandable tubular member. In an exemplaryembodiment, the method further includes not permitting the position ofthe expandable tubular member to float relative to the position of thehydraulic actuator; and displacing the adjustable expansion coneupwardly relative to the expandable tubular member using the hydraulicactuator to radially expand and plastically deform the end of theremaining portion of the expandable tubular member that overlaps withthe preexisting wellbore casing after not permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator.

A method of radially expanding and plastically deforming a tubularmember has been described that includes positioning the tubular memberwithin a preexisting structure; radially expanding and plasticallydeforming a lower portion of the tubular member to form a bell section;and radially expanding and plastically deforming a portion of thetubular member above the bell section. In an exemplary embodiment,positioning the tubular member within a preexisting structure includeslocking the tubular member to an expansion device. In an exemplaryembodiment, the outside diameter of the expansion device is less thanthe inside diameter of the tubular member. In an exemplary embodiment,the expansion device is positioned within the tubular member. In anexemplary embodiment, the expansion device includes an adjustableexpansion device. In an exemplary embodiment, the adjustable expansiondevice is adjustable to a plurality of sizes. In an exemplaryembodiment, the expansion device includes a plurality of expansiondevices. In an exemplary embodiment, at least one of the expansiondevices includes an adjustable expansion device. In an exemplaryembodiment, at least one of the adjustable expansion device isadjustable to a plurality of sizes. In an exemplary embodiment, radiallyexpanding and plastically deforming a lower portion of the tubularmember to form a bell section includes lowering an expansion device outof an end of the tubular member; and pulling the expansion devicethrough the end of the tubular member. In an exemplary embodiment,lowering an expansion device out of an end of the tubular memberincludes lowering the expansion device out of the end of the tubularmember; and adjusting the size of the expansion device. In an exemplaryembodiment, the adjustable expansion device is adjustable to a pluralityof sizes. In an exemplary embodiment, the expansion device includes aplurality of adjustable expansion devices. In an exemplary embodiment,at least one of the adjustable expansion devices is adjustable to aplurality of sizes. In an exemplary embodiment, pulling the expansiondevice through the end of the tubular member includes gripping thetubular member; and pulling an expansion device through an end of thetubular member. In an exemplary embodiment, gripping the tubular memberincludes permitting axial displacement of the tubular member in a firstdirection; and not permitting axial displacement of the tubular memberin a second direction. In an exemplary embodiment, pulling the expansiondevice through the end of the tubular member includes pulling theexpansion device through the end of the tubular member using anactuator. In an exemplary embodiment, radially expanding and plasticallydeforming a portion of the tubular member above the bell sectionincludes lowering an expansion device out of an end of the tubularmember; and pulling the expansion device through the end of the tubularmember. In an exemplary embodiment, lowering an expansion device out ofan end of the tubular member includes lowering the expansion device outof the end of the tubular member; and adjusting the size of theexpansion device. In an exemplary embodiment, the adjustable expansiondevice is adjustable to a plurality of sizes. In an exemplaryembodiment, the expansion device includes a plurality of adjustableexpansion devices. In an exemplary embodiment, at least one of theadjustable expansion devices is adjustable to a plurality of sizes. Inan exemplary embodiment, pulling the expansion device through the end ofthe tubular member includes gripping the tubular member; and pulling anexpansion device through an end of the tubular member. In an exemplaryembodiment, gripping the tubular member includes permitting axialdisplacement of the tubular member in a first direction; and notpermitting axial displacement of the tubular member in a seconddirection. In an exemplary embodiment, pulling the expansion devicethrough the end of the tubular member includes pulling the expansiondevice through the end of the tubular member using an actuator. In anexemplary embodiment, pulling the expansion device through the end ofthe tubular member includes pulling the expansion device through the endof the tubular member using fluid pressure. In an exemplary embodiment,pulling the expansion device through the end of the tubular member usingfluid pressure includes pressurizing an annulus within the tubularmember above the expansion device. In an exemplary embodiment, radiallyexpanding and plastically deforming a portion of the tubular memberabove the bell section includes fluidicly sealing an end of the tubularmember; and pulling the expansion device through the tubular member. Inan exemplary embodiment, the expansion device is adjustable. In anexemplary embodiment, the expansion device is adjustable to a pluralityof sizes. In an exemplary embodiment, the expansion device comprises aplurality of adjustable expansion devices. In an exemplary embodiment,at least one of the adjustable expansion devices is adjustable to aplurality of sizes. In an exemplary embodiment, pulling the expansiondevice through the end of the tubular member includes gripping thetubular member; and pulling an expansion device through an end of thetubular member. In an exemplary embodiment, gripping the tubular memberincludes permitting axial displacement of the tubular member in a firstdirection; and not permitting axial displacement of the tubular memberin a second direction. In an exemplary embodiment, pulling the expansiondevice through the end of the tubular member includes pulling theexpansion device through the end of the tubular member using anactuator. In an exemplary embodiment, pulling the expansion devicethrough the end of the tubular member includes pulling the expansiondevice through the end of the tubular member using fluid pressure. In anexemplary embodiment, pulling the expansion device through the end ofthe tubular member using fluid pressure includes pressurizing an annuluswithin the tubular member above the expansion device. In an exemplaryembodiment, radially expanding and plastically deforming a portion ofthe tubular member above the bell section includes overlapping theportion of the tubular member above the bell section with an end of apreexisting tubular member; and pulling an expansion device through theoverlapping portions of the tubular member and the preexisting tubularmember. In an exemplary embodiment, the expansion device is adjustable.In an exemplary embodiment, the expansion device is adjustable to aplurality of sizes. In an exemplary embodiment, the expansion deviceincludes a plurality of adjustable expansion devices. In an exemplaryembodiment, at least one of the adjustable expansion devices isadjustable to a plurality of sizes. In an exemplary embodiment, pullingthe expansion device through the overlapping portions of the tubularmember and the preexisting tubular member includes gripping the tubularmember; and pulling the expansion device through the overlappingportions of the tubular member and the preexisting tubular member. In anexemplary embodiment, gripping the tubular member includes permittingaxial displacement of the tubular member in a first direction; and notpermitting axial displacement of the tubular member in a seconddirection. In an exemplary embodiment, pulling the expansion devicethrough the overlapping portions of the tubular member and thepreexisting tubular member includes pulling the expansion device throughthe overlapping portions of the tubular member and the preexistingtubular member using an actuator. In an exemplary embodiment, pullingthe expansion device through the overlapping portions of the tubularmember and the preexisting tubular member includes pulling the expansiondevice through the overlapping portions of the tubular member and thepreexisting tubular member using fluid pressure. In an exemplaryembodiment, pulling the expansion device through the overlappingportions of the tubular member and the preexisting tubular member usingfluid pressure includes pressurizing an annulus within the tubularmember above the expansion device. In an exemplary embodiment, themethod further includes cutting an end of the portion of the tubularmember that overlaps with the preexisting tubular member. In anexemplary embodiment, the method further includes removing the cut offend of the expandable tubular member from the preexisting structure. Inan exemplary embodiment, the method further includes injecting ahardenable fluidic sealing material into an annulus between theexpandable tubular member and the preexisting structure. In an exemplaryembodiment, the method further includes cutting off an end of theexpandable tubular member. In an exemplary embodiment, the methodfurther includes removing the cut off end of the expandable tubularmember from the preexisting structure.

A method of radially expanding and plastically deforming a tubularmember has been described that includes applying internal pressure tothe inside surface of the tubular member at a plurality of discretelocation separated from one another.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole having a preexisting wellbore casinghas been described that includes means for positioning the tubularmember within the borehole in overlapping relation to the wellborecasing; means for radially expanding and plastically deforming a portionof the tubular member to form a bell section; and means for radiallyexpanding and plastically deforming a portion of the tubular memberabove the bell section comprising a portion of the tubular member thatoverlaps with the wellbore casing; wherein the inside diameter of thebell section is greater than the inside diameter of the radiallyexpanded and plastically deformed portion of the tubular member abovethe bell section. In an exemplary embodiment, means for radiallyexpanding and plastically deforming a portion of the tubular member toform a bell section includes means for positioning an adjustableexpansion device within the expandable tubular member; means forsupporting the expandable tubular member and the adjustable expansiondevice within the borehole; means for lowering the adjustable expansiondevice out of the expandable tubular member; means for increasing theoutside dimension of the adjustable expansion device; and means fordisplacing the adjustable expansion device upwardly relative to theexpandable tubular member n times to radially expand and plasticallydeform n portions of the expandable tubular member, wherein n is greaterthan or equal to 1.

A system for forming a mono diameter wellbore casing has been describedthat includes means for positioning an adjustable expansion devicewithin a first expandable tubular member; means for supporting the firstexpandable tubular member and the adjustable expansion device within aborehole; means for lowering the adjustable expansion device out of thefirst expandable tubular member; means for increasing the outsidedimension of the adjustable expansion device; means for displacing theadjustable expansion device upwardly relative to the first expandabletubular member m times to radially expand and plastically deform mportions of the first expandable tubular member within the borehole;means for positioning the adjustable expansion device within a secondexpandable tubular member; means for supporting the second expandabletubular member and the adjustable expansion device within the boreholein overlapping relation to the first expandable tubular member; meansfor lowering the adjustable expansion device out of the secondexpandable tubular member; means for increasing the outside dimension ofthe adjustable expansion device; and means for displacing the adjustableexpansion device upwardly relative to the second expandable tubularmember n times to radially expand and plastically deform n portions ofthe second expandable tubular member within the borehole.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includes meansfor positioning an adjustable expansion device within the expandabletubular member; means for supporting the expandable tubular member andthe adjustable expansion device within the borehole; means for loweringthe adjustable expansion device out of the expandable tubular member;means for increasing the outside dimension of the adjustable expansiondevice; means for displacing the adjustable expansion mandrel upwardlyrelative to the expandable tubular member n times to radially expand andplastically deform n portions of the expandable tubular member withinthe borehole; and means for pressurizing an interior region of theexpandable tubular member above the adjustable expansion device duringthe radial expansion and plastic deformation of the expandable tubularmember within the borehole.

A system for forming a mono diameter wellbore casing has been describedthat includes means for positioning an adjustable expansion devicewithin a first expandable tubular member; means for supporting the firstexpandable tubular member and the adjustable expansion device within aborehole; means for lowering the adjustable expansion device out of thefirst expandable tubular member; means for increasing the outsidedimension of the adjustable expansion device; means for displacing theadjustable expansion device upwardly relative to the first expandabletubular member m times to radially expand and plastically deform mportions of the first expandable tubular member within the borehole;means for pressurizing an interior region of the first expandabletubular member above the adjustable expansion device during the radialexpansion and plastic deformation of the first expandable tubular memberwithin the borehole; means for positioning the adjustable expansionmandrel within a second expandable tubular member; means for supportingthe second expandable tubular member and the adjustable expansionmandrel within the borehole in overlapping relation to the firstexpandable tubular member; means for lowering the adjustable expansionmandrel out of the second expandable tubular member; means forincreasing the outside dimension of the adjustable expansion mandrel;means for displacing the adjustable expansion mandrel upwardly relativeto the second expandable tubular member n times to radially expand andplastically deform n portions of the second expandable tubular memberwithin the borehole; and means for pressurizing an interior region ofthe second expandable tubular member above the adjustable expansionmandrel during the radial expansion and plastic deformation of thesecond expandable tubular member within the borehole.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includes meansfor positioning first and second adjustable expansion devices within theexpandable tubular member; means for supporting the expandable tubularmember and the first and second adjustable expansion devices within theborehole; means for lowering the first adjustable expansion device outof the expandable tubular member; means for increasing the outsidedimension of the first adjustable expansion device; means for displacingthe first adjustable expansion device upwardly relative to theexpandable tubular member to radially expand and plastically deform alower portion of the expandable tubular member; means for displacing thefirst adjustable expansion device and the second adjustable expansiondevice downwardly relative to the expandable tubular member; means fordecreasing the outside dimension of the first adjustable expansiondevice and increasing the outside dimension of the second adjustableexpansion device; means for displacing the second adjustable expansiondevice upwardly relative to the expandable tubular member to radiallyexpand and plastically deform portions of the expandable tubular memberabove the lower portion of the expandable tubular member; wherein theoutside dimension of the first adjustable expansion device is greaterthan the outside dimension of the second adjustable expansion device.

A system for forming a mono diameter wellbore casing has been describedthat includes means for positioning first and second adjustableexpansion devices within a first expandable tubular member; means forsupporting the first expandable tubular member and the first and secondadjustable expansion devices within a borehole; means for lowering thefirst adjustable expansion device out of the first expandable tubularmember; means for increasing the outside dimension of the firstadjustable expansion device; displacing the first adjustable expansiondevice upwardly relative to the first expandable tubular member toradially expand and plastically deform a lower portion of the firstexpandable tubular member; means for displacing the first adjustableexpansion device and the second adjustable expansion device downwardlyrelative to the first expandable tubular member; means for decreasingthe outside dimension of the first adjustable expansion device andincreasing the outside dimension of the second adjustable expansiondevice; means for displacing the second adjustable expansion deviceupwardly relative to the first expandable tubular member to radiallyexpand and plastically deform portions of the first expandable tubularmember above the lower portion of the expandable tubular member; meansfor positioning first and second adjustable expansion devices within asecond expandable tubular member; means for supporting the firstexpandable tubular member and the first and second adjustable expansiondevices within the borehole in overlapping relation to the firstexpandable tubular member; means for lowering the first adjustableexpansion device out of the second expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; means for displacing the adjustable expansion device upwardlyrelative to the second expandable tubular member to radially expand andplastically deform a lower portion of the second expandable tubularmember; means for displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the secondexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; and means fordisplacing the second adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform portions of the second expandable tubular member above the lowerportion of the second expandable tubular member; wherein the outsidedimension of the first adjustable expansion device is greater than theoutside dimension of the second adjustable expansion device.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includes meansfor positioning first and second adjustable expansion devices within theexpandable tubular member; means for supporting the expandable tubularmember and the first and second adjustable expansion devices within theborehole; means for lowering the first adjustable expansion device outof the expandable tubular member; means for increasing the outsidedimension of the first adjustable expansion device; means for displacingthe first adjustable expansion device upwardly relative to theexpandable tubular member to radially expand and plastically deform alower portion of the expandable tubular member; means for pressurizingan interior region of the expandable tubular member above the firstadjustable expansion device during the radial expansion of the lowerportion of the expandable tubular member by the first adjustableexpansion device; means for displacing the first adjustable expansiondevice and the second adjustable expansion device downwardly relative tothe expandable tubular member; means for decreasing the outsidedimension of the first adjustable expansion device and increasing theoutside dimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe expandable tubular member to radially expand and plastically deformportions of the expandable tubular member above the lower portion of theexpandable tubular member; and means for pressurizing an interior regionof the expandable tubular member above the second adjustable expansiondevice during the radial expansion of the portions of the expandabletubular member above the lower portion of the expandable tubular memberby the second adjustable expansion device; wherein the outside dimensionof the first adjustable expansion device is greater than the outsidedimension of the second adjustable expansion device.

A system for forming a mono diameter wellbore casing has been describedthat includes means for positioning first and second adjustableexpansion devices within a first expandable tubular member; means forsupporting the first expandable tubular member and the first and secondadjustable expansion devices within a borehole; means for lowering thefirst adjustable expansion device out of the first expandable tubularmember; means for increasing the outside dimension of the firstadjustable expansion device; means for displacing the first adjustableexpansion device upwardly relative to the first expandable tubularmember to radially expand and plastically deform a lower portion of thefirst expandable tubular member; means for pressurizing an interiorregion of the first expandable tubular member above the first adjustableexpansion device during the radial expansion of the lower portion of thefirst expandable tubular member by the first adjustable expansiondevice; means for displacing the first adjustable expansion device andthe second adjustable expansion device downwardly relative to the firstexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe first expandable tubular member to radially expand and plasticallydeform portions of the first expandable tubular member above the lowerportion of the expandable tubular member; means for pressurizing aninterior region of the first expandable tubular member above the secondadjustable expansion device during the radial expansion of the portionsof the first expandable tubular member above the lower portion of thefirst expandable tubular member by the second adjustable expansiondevice; means for positioning first and second adjustable expansiondevices within a second expandable tubular member; means for supportingthe first expandable tubular member and the first and second adjustableexpansion devices within the borehole in overlapping relation to thefirst expandable tubular member; means for lowering the first adjustableexpansion device out of the second expandable tubular member; means forincreasing the outside dimension of the first adjustable expansiondevice; means for displacing the first adjustable expansion deviceupwardly relative to the second expandable tubular member to radiallyexpand and plastically deform a lower portion of the second expandabletubular member; means for pressurizing an interior region of the secondexpandable tubular member above the first adjustable expansion deviceduring the radial expansion of the lower portion of the secondexpandable tubular member by the first adjustable expansion device;means for displacing the first adjustable expansion device and thesecond adjustable expansion device downwardly relative to the secondexpandable tubular member; means for decreasing the outside dimension ofthe first adjustable expansion device and increasing the outsidedimension of the second adjustable expansion device; means fordisplacing the second adjustable expansion device upwardly relative tothe second expandable tubular member to radially expand and plasticallydeform portions of the second expandable tubular member above the lowerportion of the second expandable tubular member; and means forpressurizing an interior region of the second expandable tubular memberabove the second adjustable expansion device during the radial expansionof the portions of the second expandable tubular member above the lowerportion of the second expandable tubular member by the second adjustableexpansion device; wherein the outside dimension of the first adjustableexpansion device is greater than the outside dimension of the secondadjustable expansion device.

A system for radially expanding and plastically deforming an expandabletubular member within a borehole has been described that includes meansfor supporting the expandable tubular member, an hydraulic actuator, andan adjustable expansion device within the borehole; means for increasingthe size of the adjustable expansion device; and means for displacingthe adjustable expansion device upwardly relative to the expandabletubular member using the hydraulic actuator to radially expand andplastically deform a portion of the expandable tubular member. In anexemplary embodiment, the system further includes means for reducing thesize of the adjustable expansion device after the portion of theexpandable tubular member has been radially expanded and plasticallydeformed. In an exemplary embodiment, the system further includes meansfor fluidicly sealing the radially expanded and plastically deformed endof the expandable tubular member after reducing the size of theadjustable expansion device. In an exemplary embodiment, the systemfurther includes means for permitting the position of the expandabletubular member to float relative to the position of the hydraulicactuator after fluidicly sealing the radially expanded and plasticallydeformed end of the expandable tubular member. In an exemplaryembodiment, the system further includes means for injecting a hardenablefluidic sealing material into an annulus between the expandable tubularmember and a preexisting structure after permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator. In an exemplary embodiment, the system furtherincludes means for increasing the size of the adjustable expansiondevice after permitting the position of the expandable tubular member tofloat relative to the position of the hydraulic actuator. In anexemplary embodiment, system further includes means for displacing theadjustable expansion cone upwardly relative to the expandable tubularmember to radially expand and plastically deform another portion of theexpandable tubular member. In an exemplary embodiment, the systemfurther includes if the end of the other portion of the expandabletubular member overlaps with a preexisting structure, then means for notpermitting the position of the expandable tubular member to floatrelative to the position of the hydraulic actuator; and means fordisplacing the adjustable expansion cone upwardly relative to theexpandable tubular member using the hydraulic actuator to radiallyexpand and plastically deform the end of the other portion of theexpandable tubular member that overlaps with the preexisting structure.

A system for forming a mono diameter wellbore casing within a boreholethat includes a preexisting wellbore casing has been described thatincludes means for supporting the expandable tubular member, anhydraulic actuator, and an adjustable expansion device within theborehole; means for increasing the size of the adjustable expansiondevice; means for displacing the adjustable expansion device upwardlyrelative to the expandable tubular member using the hydraulic actuatorto radially expand and plastically deform a portion of the expandabletubular member; and means for displacing the adjustable expansion deviceupwardly relative to the expandable tubular member to radially expandand plastically deform the remaining portion of the expandable tubularmember and a portion of the preexisting wellbore casing that overlapswith an end of the remaining portion of the expandable tubular member.In an exemplary embodiment, the system further includes means forreducing the size of the adjustable expansion device after the portionof the expandable tubular member has been radially expanded andplastically deformed. In an exemplary embodiment, the system furtherincludes means for fluidicly sealing the radially expanded andplastically deformed end of the expandable tubular member after reducingthe size of the adjustable expansion device. In an exemplary embodiment,the system further includes means for permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator after fluidicly sealing the radially expanded andplastically deformed end of the expandable tubular member. In anexemplary embodiment, the system further includes means for injecting ahardenable fluidic sealing material into an annulus between theexpandable tubular member and the borehole after permitting the positionof the expandable tubular member to float relative to the position ofthe hydraulic actuator. In an exemplary embodiment, the system furtherincludes means for increasing the size of the adjustable expansiondevice after permitting the position of the expandable tubular member tofloat relative to the position of the hydraulic actuator. In anexemplary embodiment, the system further includes means for displacingthe adjustable expansion cone upwardly relative to the expandabletubular member to radially expand and plastically deform the remainingportion of the expandable tubular member. In an exemplary embodiment,the system further includes means for not permitting the position of theexpandable tubular member to float relative to the position of thehydraulic actuator; and means for displacing the adjustable expansioncone upwardly relative to the expandable tubular member using thehydraulic actuator to radially expand and plastically deform the end ofthe remaining portion of the expandable tubular member that overlapswith the preexisting wellbore casing after not permitting the positionof the expandable tubular member to float relative to the position ofthe hydraulic actuator.

A system for radially expanding and plastically deforming a tubularmember has been described that includes means for positioning thetubular member within a preexisting structure; means for radiallyexpanding and plastically deforming a lower portion of the tubularmember to form a bell section; and means for radially expanding andplastically deforming a portion of the tubular member above the bellsection. In an exemplary embodiment, positioning the tubular memberwithin a preexisting structure includes means for locking the tubularmember to an expansion device. In an exemplary embodiment, the outsidediameter of the expansion device is less than the inside diameter of thetubular member. In an exemplary embodiment, the expansion device ispositioned within the tubular member. In an exemplary embodiment, theexpansion device includes an adjustable expansion device. In anexemplary embodiment, the adjustable expansion device is adjustable to aplurality of sizes. In an exemplary embodiment, the expansion deviceincludes a plurality of expansion devices. In an exemplary embodiment,at least one of the expansion devices includes an adjustable expansiondevice. In an exemplary embodiment, at least one of the adjustableexpansion device is adjustable to a plurality of sizes. In an exemplaryembodiment, means for radially expanding and plastically deforming alower portion of the tubular member to form a bell section includesmeans for lowering an expansion device out of an end of the tubularmember; and means for pulling the expansion device through the end ofthe tubular member. In an exemplary embodiment, means for lowering anexpansion device out of an end of the tubular member includes means forlowering the expansion device out of the end of the tubular member; andmeans for adjusting the size of the expansion device. In an exemplaryembodiment, the adjustable expansion device is adjustable to a pluralityof sizes. In an exemplary embodiment, the expansion device includes aplurality of adjustable expansion devices. In an exemplary embodiment,at least one of the adjustable expansion devices is adjustable to aplurality of sizes. In an exemplary embodiment, means for pulling theexpansion device through the end of the tubular member includes meansfor gripping the tubular member; and means for pulling an expansiondevice through an end of the tubular member. In an exemplary embodiment,means for gripping the tubular member includes means for permittingaxial displacement of the tubular member in a first direction; and meansfor not permitting axial displacement of the tubular member in a seconddirection. In an exemplary embodiment, means for pulling the expansiondevice through the end of the tubular member includes means for pullingthe expansion device through the end of the tubular member using anactuator. In an exemplary embodiment, means for radially expanding andplastically deforming a portion of the tubular member above the bellsection includes means for lowering an expansion device out of an end ofthe tubular member; and means for pulling the expansion device throughthe end of the tubular member. In an exemplary embodiment, means forlowering an expansion device out of an end of the tubular memberincludes means for lowering the expansion device out of the end of thetubular member; and means for adjusting the size of the expansiondevice. In an exemplary embodiment, the adjustable expansion device isadjustable to a plurality of sizes. In an exemplary embodiment, theexpansion device comprises a plurality of adjustable expansion devices.In an exemplary embodiment, at least one of the adjustable expansiondevices is adjustable to a plurality of sizes. In an exemplaryembodiment, means for pulling the expansion device through the end ofthe tubular member includes means for gripping the tubular member; andmeans for pulling an expansion device through an end of the tubularmember. In an exemplary embodiment, means for gripping the tubularmember includes means for permitting axial displacement of the tubularmember in a first direction; and means for not permitting axialdisplacement of the tubular member in a second direction. In anexemplary embodiment, means for pulling the expansion device through theend of the tubular member includes means for pulling the expansiondevice through the end of the tubular member using an actuator. In anexemplary embodiment, means for pulling the expansion device through theend of the tubular member includes means for pulling the expansiondevice through the end of the tubular member using fluid pressure. In anexemplary embodiment, means for pulling the expansion device through theend of the tubular member using fluid pressure includes means forpressurizing an annulus within the tubular member above the expansiondevice. In an exemplary embodiment, means for radially expanding andplastically deforming a portion of the tubular member above the bellsection includes means for fluidicly sealing an end of the tubularmember; and means for pulling the expansion device through the tubularmember. In an exemplary embodiment, the expansion device is adjustable.In an exemplary embodiment, the expansion device is adjustable to aplurality of sizes. In an exemplary embodiment, the expansion deviceincludes a plurality of adjustable expansion devices. In an exemplaryembodiment, at least one of the adjustable expansion devices isadjustable to a plurality of sizes. In an exemplary embodiment, meansfor pulling the expansion device through the end of the tubular memberincludes means for gripping the tubular member; and means for pulling anexpansion device through an end of the tubular member. In an exemplaryembodiment, means for gripping the tubular member includes means forpermitting axial displacement of the tubular member in a firstdirection; and means for not permitting axial displacement of thetubular member in a second direction. In an exemplary embodiment, meansfor pulling the expansion device through the end of the tubular memberincludes means for pulling the expansion device through the end of thetubular member using an actuator. In an exemplary embodiment, means forpulling the expansion device through the end of the tubular memberincludes means for pulling the expansion device through the end of thetubular member using fluid pressure. In an exemplary embodiment, meansfor pulling the expansion device through the end of the tubular memberusing fluid pressure includes means for pressurizing an annulus withinthe tubular member above the expansion device. In an exemplaryembodiment, means for radially expanding and plastically deforming aportion of the tubular member above the bell section includes means foroverlapping the portion of the tubular member above the bell sectionwith an end of a preexisting tubular member; and means for pulling anexpansion device through the overlapping portions of the tubular memberand the preexisting tubular member. In an exemplary embodiment, theexpansion device is adjustable. In an exemplary embodiment, theexpansion device is adjustable to a plurality of sizes. In an exemplaryembodiment, the expansion device includes a plurality of adjustableexpansion devices. In an exemplary embodiment, at least one of theadjustable expansion devices is adjustable to a plurality of sizes. Inan exemplary embodiment, means for pulling the expansion device throughthe overlapping portions of the tubular member and the preexistingtubular member includes means for gripping the tubular member; and meansfor pulling the expansion device through the overlapping portions of thetubular member and the preexisting tubular member. In an exemplaryembodiment, means for gripping the tubular member includes means forpermitting axial displacement of the tubular member in a firstdirection; and means for not permitting axial displacement of thetubular member in a second direction. In an exemplary embodiment, meansfor pulling the expansion device through the overlapping portions of thetubular member and the preexisting tubular member includes means forpulling the expansion device through the overlapping portions of thetubular member and the preexisting tubular member using an actuator. Inan exemplary embodiment, means for pulling the expansion device throughthe overlapping portions of the tubular member and the preexistingtubular member includes means for pulling the expansion device throughthe overlapping portions of the tubular member and the preexistingtubular member using fluid pressure. In an exemplary embodiment, meansfor pulling the expansion device through the overlapping portions of thetubular member and the preexisting tubular member using fluid pressureincludes means for pressurizing an annulus within the tubular memberabove the expansion device. In an exemplary embodiment, the systemfurther includes means for cutting an end of the portion of the tubularmember that overlaps with the preexisting tubular member. In anexemplary embodiment, the system further includes means for removing thecut off end of the expandable tubular member from the preexistingstructure. In an exemplary embodiment, the system further includes meansfor injecting a hardenable fluidic sealing material into an annulusbetween the expandable tubular member and the preexisting structure. Inan exemplary embodiment, the system further includes means for cuttingoff an end of the expandable tubular member. In an exemplary embodiment,the system further includes means for removing the cut off end of theexpandable tubular member from the preexisting structure.

A system of radially expanding and plastically deforming a tubularmember has been described that includes a support member; and means forapplying internal pressure to the inside surface of the tubular memberat a plurality of discrete location separated from one another coupledto the support member.

A method of cutting a tubular member has been described that includespositioning a plurality of cutting elements within the tubular member;and bringing the cutting elements into engagement with the tubularmember. In an exemplary embodiment, the cutting elements include a firstgroup of cutting elements; and a second group of cutting elements;wherein the first group of cutting elements are interleaved with thesecond group of cutting elements. In an exemplary embodiment, bringingthe cutting elements into engagement with the tubular member includesbringing the cutting elements into axial alignment. In an exemplaryembodiment, bringing the cutting elements into engagement with thetubular member further includes pivoting the cutting elements. In anexemplary embodiment, bringing the cutting elements into engagement withthe tubular member further includes translating the cutting elements. Inan exemplary embodiment, bringing the cutting elements into engagementwith the tubular member further includes pivoting the cutting elements;and translating the cutting elements. In an exemplary embodiment,bringing the cutting elements into engagement with the tubular memberincludes rotating the cutting elements about a common axis. In anexemplary embodiment, bringing the cutting elements into engagement withthe tubular member includes pivoting the cutting elements aboutcorresponding axes; translating the cutting elements; and rotating thecutting elements about a common axis. In an exemplary embodiment, themethod further includes preventing the cutting elements from coming intoengagement with the tubular member if the inside diameter of the tubularmember is less than a predetermined value. In an exemplary embodiment,preventing the cutting elements from coming into engagement with thetubular member if the inside diameter of the tubular member is less thana predetermined value includes sensing the inside diameter of thetubular member.

A method of gripping a tubular member has been described that includespositioning a plurality of gripping elements within the tubular member;bringing the gripping elements into engagement with the tubular member.In an exemplary embodiment, bringing the gripping elements intoengagement with the tubular member includes displacing the grippingelements in an axial direction; and displacing the gripping elements ina radial direction. In an exemplary embodiment, the method furtherincludes biasing the gripping elements against engagement with thetubular member.

A method of operating an actuator has been described that includespressurizing a plurality of pressure chamber. In an exemplaryembodiment, the method further includes transmitting torsional loads.

A method of injecting a hardenable fluidic sealing material into anannulus between a tubular member and a preexisting structure has beendescribed that includes positioning the tubular member into thepreexisting structure; sealing off an end of the tubular member;operating a valve within the end of the tubular member; and injecting ahardenable fluidic sealing material through the valve into the annulusbetween the tubular member and the preexisting structure.

A system for cutting a tubular member has been described that includesmeans for positioning a plurality of cutting elements within the tubularmember; and means for bringing the cutting elements into engagement withthe tubular member. In an exemplary embodiment, the cutting elementsinclude a first group of cutting elements; and a second group of cuttingelements; wherein the first group of cutting elements are interleavedwith the second group of cutting elements. In an exemplary embodiment,means for bringing the cutting elements into engagement with the tubularmember includes means for bringing the cutting elements into axialalignment. In an exemplary embodiment, means for bringing the cuttingelements into engagement with the tubular member further includes meansfor pivoting the cutting elements. In an exemplary embodiment, means forbringing the cutting elements into engagement with the tubular memberfurther includes means for translating the cutting elements. In anexemplary embodiment, means for bringing the cutting elements intoengagement with the tubular member further includes means for pivotingthe cutting elements; and means for translating the cutting elements. Inan exemplary embodiment, means for bringing the cutting elements intoengagement with the tubular member includes means for rotating thecutting elements about a common axis. In an exemplary embodiment, meansfor bringing the cutting elements into engagement with the tubularmember includes means for pivoting the cutting elements aboutcorresponding axes; means for translating the cutting elements; andmeans for rotating the cutting elements about a common axis. In anexemplary embodiment, the system further includes means for preventingthe cutting elements from coming into engagement with the tubular memberif the inside diameter of the tubular member is less than apredetermined value. In an exemplary embodiment, means for preventingthe cutting elements from coming into engagement with the tubular memberif the inside diameter of the tubular member is less than apredetermined value includes means for sensing the inside diameter ofthe tubular member.

A system for gripping a tubular member has been described that includesmeans for positioning a plurality of gripping elements within thetubular member; and means for bringing the gripping elements intoengagement with the tubular member. In an exemplary embodiment, meansfor bringing the gripping elements into engagement with the tubularmember includes means for displacing the gripping elements in an axialdirection; and means for displacing the gripping elements in a radialdirection. In an exemplary embodiment, the system further includes meansfor biasing the gripping elements against engagement with the tubularmember.

An actuator system has been described that includes a support member;and means for pressurizing a plurality of pressure chambers coupled tothe support member. In an exemplary embodiment, the system furtherincludes means for transmitting torsional loads.

A system for injecting a hardenable fluidic sealing material into anannulus between a tubular member and a preexisting structure has beendescribed that includes means for positioning the tubular member intothe preexisting structure; means for sealing off an end of the tubularmember; means for operating a valve within the end of the tubularmember; and means for injecting a hardenable fluidic sealing materialthrough the valve into the annulus between the tubular member and thepreexisting structure.

A method of engaging a tubular member has been described that includespositioning a plurality of elements within the tubular member; andbringing the elements into engagement with the tubular member. In anexemplary embodiment, the elements include a first group of elements;and a second group of elements; wherein the first group of elements areinterleaved with the second group of elements. In an exemplaryembodiment, bringing the elements into engagement with the tubularmember includes bringing the elements into axial alignment. In anexemplary embodiment, bringing the elements into engagement with thetubular member further includes pivoting the elements. In an exemplaryembodiment, bringing the elements into engagement with the tubularmember further includes translating the elements. In an exemplaryembodiment, bringing the elements into engagement with the tubularmember further includes pivoting the elements; and translating theelements. In an exemplary embodiment, bringing the elements intoengagement with the tubular member includes rotating the elements abouta common axis. In an exemplary embodiment, bringing the elements intoengagement with the tubular member includes pivoting the elements aboutcorresponding axes; translating the elements; and rotating the elementsabout a common axis. In an exemplary embodiment, the method furtherincludes preventing the elements from coming into engagement with thetubular member if the inside diameter of the tubular member is less thana predetermined value. In an exemplary embodiment, preventing theelements from coming into engagement with the tubular member if theinside diameter of the tubular member is less than a predetermined valueincludes sensing the inside diameter of the tubular member.

A system for engaging a tubular member has been described that includesmeans for positioning a plurality of elements within the tubular member;and means for bringing the elements into engagement with the tubularmember. In an exemplary embodiment, the elements include a first groupof elements; and a second group of elements; wherein the first group ofelements are interleaved with the second group of elements. In anexemplary embodiment, means for bringing the elements into engagementwith the tubular member includes means for bringing the elements intoaxial alignment. In an exemplary embodiment, means for bringing theelements into engagement with the tubular member further includes meansfor pivoting the elements. In an exemplary embodiment, means forbringing the elements into engagement with the tubular member furtherincludes means for translating the elements. In an exemplary embodiment,means for bringing the elements into engagement with the tubular memberfurther includes means for pivoting the elements; and means fortranslating the elements. In an exemplary embodiment, means for bringingthe elements into engagement with the tubular member includes means forrotating the elements about a common axis. In an exemplary embodiment,means for bringing the elements into engagement with the tubular memberincludes means for pivoting the elements about corresponding axes; meansfor translating the elements; and means for rotating the elements abouta common axis. In an exemplary embodiment, the system further includesmeans for preventing the elements from coming into engagement with thetubular member if the inside diameter of the tubular member is less thana predetermined value. In an exemplary embodiment, means for preventingthe elements from coming into engagement with the tubular member if theinside diameter of the tubular member is less than a predetermined valueincludes means for sensing the inside diameter of the tubular member.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the teachings ofthe present illustrative embodiments may be used to provide a wellborecasing, a pipeline, or a structural support. Furthermore, the elementsand teachings of the various illustrative embodiments may be combined inwhole or in part in some or all of the illustrative embodiments.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. An apparatus for radially expanding and plastically deforming anexpandable tubular member, comprising: a support member; an expansiondevice for radially expanding and plastically deforming the tubularmember coupled to the support member; an actuator coupled to the supportmember for displacing the expansion device relative to the supportmember; a gripping device for gripping the tubular member coupled to thesupport member; and a cutting device for cutting the tubular membercoupled to the support member, wherein the gripping device comprises aplurality of movable gripping elements, wherein the gripping elementsare moveable in an axial direction relative to the support member. 2.The apparatus of claim 1, wherein the gripping elements are moveable ina radial and an axial direction relative to the support member.
 3. Theapparatus of claim 1, wherein the gripping elements are moveable from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, during the movement from the first position to the secondposition, the gripping elements move in a radial and an axial directionrelative to the support member.
 4. The apparatus of claim 1, wherein thegripping elements are moveable from a first position to a secondposition; wherein in the first position, the gripping elements do notengage the tubular member; wherein in the second position, the grippingelements do engage the tubular member; and wherein, during the movementfrom the first position to the second position, the gripping elementsmove in an axial direction relative to the support member.
 5. Theapparatus of claim 1, wherein, if the tubular member is displaced in afirst axial direction, the gripping device grips the tubular member; andwherein, if the tubular member is displaced in a second axial direction,the gripping device does not grip the tubular member.
 6. The apparatusof claim 1, wherein the gripping elements are moveable from a firstposition to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein, the gripping elements are biased to remain in the firstposition.
 7. The apparatus of claim 1, wherein the gripping devicefurther composes: an actuator for moving the gripping elements from afirst position to a second position; wherein in the first position, thegripping elements do not engage the tubular member; wherein in thesecond position, the gripping elements do engage the tubular member; andwherein the actuator is a fluid powered actuator.
 8. The apparatus ofclaim 1, further comprising a sealing assembly for sealing an annulusdefined between the support member and the tubular member, wherein thesealing device seals an annulus defines between the support member andthe tubular member.
 9. The apparatus of claim 1, further comprising: alocking device for locking the position of the tubular member relativeto the support member.
 10. The apparatus of claim 1, further comprisinga packer assembly coupled to the support member, wherein the packerassembly comprises: a packer; and a packer control device forcontrolling the operation of the packer coupled to the support member.11. The apparatus of claim 10, wherein the packer comprises: a supportmember defining a passage; a shoe comprising a float valve coupled to anend of the support member; one or more compressible packer elementsmovably coupled to the support member; and a sliding sleeve valvemovably positioned within the passage of the support member.
 12. Theapparatus of claim 10, wherein the packer control device composes asupport member; one or more drag Hocks releasably coupled to the supportmember; and a stinger coupled to the support member for engaging thepacker.
 13. The apparatus of claim 10, wherein the packer comprises: asupport member defining a passage; a shoe comprising a float valvecoupled to an end of the support member; one or more compressible packerelements movably coupled to the support member; and a sliding sleevevalve positioned within the passage of the support member; and whereinthe packer control device comprises: a support member; one or more dragblocks releasably coupled to the support member; and a stinger coupledto the support member for engaging the sliding sleeve valve.
 14. Theapparatus of claim 1, wherein the actuator comprises: a first actuatorfor pulling the expansion device; and a second actuator for pushing theexpansion device.
 15. The apparatus of claim 14, wherein the first andsecond actuators comprise means for transferring torsional loads betweenthe support member and the expansion device
 16. The apparatus of claim1, wherein the actuator comprises means for transferring torsional loadsbetween the support member and the expansion device.
 17. The apparatusof claim 1, wherein the actuator comprises a plurality of pistonspositioned within corresponding piston chambers.
 18. The apparatus ofclaim 1, wherein the expansion device comprises an adjustable expansiondevice.
 19. The apparatus of claim 1, wherein the expansion devicecomprises a plurality of expansion devices.
 20. The apparatus of claim19, wherein at least one of the expansion devices comprises anadjustable expansion device.
 21. The apparatus of claim 20, wherein theadjustable expansion device comprises: a support member; and a pluralityof movable expansion elements coupled to the support member.
 22. Theapparatus of claim 21, further comprising: an actuator coupled to thesupport member for moving the expansion elements between a firstposition and a second position; wherein in the first position, theexpansion elements do not engage the tubular member; and wherein in thesecond position, the expansion elements engage the tubular member. 23.The apparatus of claim 22, further comprising: a sensor coupled to thesupport member for sensing the internal diameter of the tubular member.24. The apparatus of claim 23, wherein the sensor prevents the expansionelements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. 25.The apparatus of claim 22, wherein the expansion elements comprise: afirst set of expansion elements; and a second set of expansion elements;wherein The first set of expansion elements are interleaved with thesecond set of expansion elements.
 26. The apparatus of claim 22, whereinin the first position, the first set of expansion elements are notaxially aligned with the second set of expansion elements.
 27. Theapparatus of claim 22, wherein in the second position, the first set ofexpansion elements are axially aligned with the second set of expansionelements.
 28. An apparatus of claim for radially expanding andplastically deforming an expandable tubular member, comprising: asupport member; an expansion device for radially expanding andplastically deforming the tubular member coupled to the support member;an actuator coupled to the support member for displacing the expansiondevice relative to the support member; a gripping device for grippingthe tubular member coupled to the support member; a cutting device forcutting the tubular member coupled to the support member, wherein thecutting device comprises a support member and a plurality of movablecutting elements coupled to the support member; an actuator coupled tothe support member for moving the cutting elements between a firstposition and a second position, wherein the cutting elements do notengage the tubular member in the first position and the cutting elementsengage the tubular member in the second position; and a sensor coupledto the support member for sensing the internal diameter of the tubularmember.
 29. The apparatus of claim 28, wherein the sensor prevents thecutting elements from being moved to the second position if the internaldiameter of the tubular member is less than a predetermined value. 30.The apparatus of claim 28, wherein the cutting elements comprise: afirst set of cutting elements; and a second set of cutting elements;wherein the first set of cutting elements are interleaved with thesecond set of cutting elements.
 31. The apparatus of claim 30, whereinin the first position, the first set of cuffing elements are not axiallyaligned with the second set of cuffing elements.
 32. The apparatus ofclaim 30, wherein in the second position, the first set of cuffingelements are axially aligned with the second set of cuffing elements.